Custom Rigid Mailer Boxes

Updated 2026-10-06

Custom rigid mailer boxes are stiff, crush-resistant mailers that protect products and flat items in transit, used by ecommerce, print, photo and luxury brands. Options range from heavy paperboard rigid mailers for documents and prints to corrugated or chipboard mailer boxes for premium products, printed with your logo. Send your size, and Vorex replies with pricing.

Resists bending and crushing
Keeps flat items flat
Logo printed outside
Made to your exact size

Get a free quote in minutes

Size, quantity and email. We reply with pricing and options.

Ships to the USA and CanadaNo obligation

When to ship in a rigid mailer

A rigid mailer is built to resist bending and crushing on the way to the customer. There are two main types. Flat rigid mailers are heavy paperboard envelopes with a flap closure, used for prints, photos, documents, calendars and thin products. Rigid mailer boxes are box-shaped mailers made from stiff corrugated or wrapped chipboard, used when a premium product needs both protection and a high-end opening.

For flat items, a thick paperboard mailer with a self-seal strip keeps contents flat without bubble wrap, and a tear strip makes opening easy. For products, custom rigid shipping boxes in E-flute or B-flute corrugated give strong walls with a mailer-style lid, while wrapped chipboard mailers deliver a luxury feel. Inserts keep items from moving, and the right size reduces filler and shifting during transit.

Print your logo and a short line on the outside of custom rigid mailers so the parcel is recognizable, and keep a clear space for the shipping label. Box-style mailers can carry richer interior print for unboxing. If you ship artwork or photography, a printed 'do not bend' note helps handlers. Our team can set up your design and send a digital proof before production.

Popular uses

Art prints and photographs
Documents and certificates
Calendars and planners
Vinyl records and flat media
Premium apparel and accessories
Luxury subscription shipments

Specifications

Size	Made to your exact inside dimensions (L × W × H)
Materials	Paperboard (SBS), kraft, corrugated (E, B or double wall), rigid chipboard
Printing	Full colour CMYK, Pantone (PMS) spot colours, inside and outside printing
Finishes	Matte, gloss or soft-touch lamination, spot UV, foil stamping, embossing, debossing
Add-ons	Window cut-outs, inserts, handles, custom tissue paper and stickers
Proof	Digital proof on your dieline before production

Request pricing for custom rigid mailer boxes

Make it yours

Options for custom rigid mailer boxes

Mailer types

Flat paperboard rigid mailers with flap closure, or box-style rigid mailers with hinged lids in corrugated or wrapped chipboard. The right type depends on what you ship.

Board

Heavy paperboard for flat mailers, E-flute or B-flute corrugated for shipping boxes, or chipboard for a premium rigid mailer. Board is chosen based on contents and route.

Printing

Print your logo, colors and messages on the outside, plus inside printing on box-style mailers for a branded reveal. Leave a clear area for the shipping label.

Closures

Self-seal adhesive strips, tear strips for easy opening, tuck-in lids or locking tabs, depending on mailer type and contents. Tear strips also show if a parcel has been opened.

Inserts

Paperboard or corrugated inserts hold products in place and reduce movement, especially for fragile or multi-item shipments. Inserts also reduce the need for loose void fill.

Eco options

Paperboard and corrugated rigid mailers are widely recyclable where facilities exist. Ask about recycled-content board and water-based inks. Paper-based mailers avoid plastic bubble lining.

How it works

Ordering custom rigid mailer boxes

Get a free quote

Request a quote
Tell us the box style, size, quantity and where it ships.
Get pricing and a proof
A specialist confirms options and sends a digital proof of your design.
Approve and print
Nothing goes to press until you approve the proof.
Delivered to your door
Boxes ship to your address in the USA or Canada.

FAQ

Custom Rigid Mailer Boxes: questions answered

Still unsure? Ask a packaging specialist.

What is a rigid mailer?

A rigid mailer is a stiff mailer made from heavy paperboard or corrugated board that resists bending. Flat versions protect documents, prints and photos, while box versions protect products and give a premium unboxing. Both can be printed with your logo.

How much does it cost to mail a rigid mailer?

Postage depends on your carrier, the mailer's size, weight and destination, so check your carrier's current rates. Sizing your custom rigid mailer closely to the contents can help keep it in a lower size or weight band.

Are rigid mailers better than bubble mailers?

Rigid mailers are better at keeping items flat and resisting bending, which suits prints and documents. Bubble mailers cushion small, irregular items. Choose based on what needs protecting most. Some brands use both, matching the mailer type to each product line.

Can rigid mailers be printed with a logo?

Yes. Logos, colors and messages can be printed on the outside, and box-style rigid mailers can be printed inside too. Leave a clear area for the shipping label. A printed handling note can also help protect flat items such as art prints.

How do I order custom rigid mailers?

Send the item dimensions, quantity, preferred mailer type, closure and artwork through the quote form. A Vorex specialist replies with pricing and sends a digital proof before production. Mention whether contents must stay flat so the board is chosen correctly.

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