Custom Rigid Packaging Mailers
Custom rigid packaging mailers from 100 — magnetic flap boxes in wrapped grayboard, specified for the trip through a parcel network as well as the unboxing, with the outer carton, corner protection and insert chosen at the same time as the wrap.
A presentation box that has to survive the post first
- Board
- Wrapped grayboard, 1.5–2 mm, magnetic flap lid
- Closure
- Concealed magnets in the flap and front wall; optional ribbon pull
- Wrap
- Printed art paper, textured paper or soft-touch laminate
Get a price for Rigid Packaging Mailers
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Shipping a rigid box on its own or inside a shipper
For anything sold above a gift-shop price we recommend the outer. A rigid mailer that arrives with a crushed corner reads as a damaged product, whatever is inside.
| Ship as it is | Label on a sleeve or a paper band, never on the wrap; corners will show wear |
|---|---|
| Inside a printed outer | A thin corrugated mailer takes the scuffs; the rigid box arrives clean |
| Inside a plain shipper with fill | Cheapest outer, but the unboxing starts with void fill |
Where the post marks a rigid wrap
- Corners: the board holds, but the paper over it scuffs through to gray.
- Soft-touch laminate: picks up rub marks from other cartons; matte or textured paper hides them.
- Dark wraps: show every scrape, so navy and black need the outer most.
- The flap edge: a magnet pulls the flap tight, but a hard knock can lift it open in transit — a sticker seal stops that.
Inside the mailer
The product should not move when the box is shaken. A wrapped card tray, an EVA or foam cut, or a paperboard platform holds it off the walls. Some rigid mailers in this range carry a window in the lid so the product is seen before the flap is opened; the window film needs the outer even more than the wrap does.
Freight before the first order ships
A rigid mailer arrives assembled, so a thousand of them take up a thousand boxes of space in your stockroom and on the truck. If storage is the problem rather than the post, our rigid foldable boxes that ship flat give the same flap and magnet in a box you assemble at packing.
Rigid Packaging Mailers — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- Wrapped grayboard, 1.5–2 mm, magnetic flap lid
- Closure
- Concealed magnets in the flap and front wall; optional ribbon pull
- Wrap
- Printed art paper, textured paper or soft-touch laminate
- Inside
- Card tray, foam or EVA cut, paperboard platform
- Outer
- Printed or plain corrugated shipper, optional
- Options
- Lid window, inside-lid print, seal sticker
- Minimum
- 100 boxes
On every job
- Print process
- The wrap is printed offset as a flat sheet and applied to the board, so the print quality is that of a sheet rather than a box.
- Color
- CMYK on the wrap with spot colors for a brand match. A textured or soft-touch wrap mutes a solid color slightly.
- Tolerance
- Board cut plus or minus 0.5 mm. Lid fit is set on a sample and held on the run, with an allowance for the delivery climate.
- Tooling
- No cutting die on the box itself. The tooling is the wrap print and any foil or emboss die, made once and kept.
- Food contact
- A food-grade liner or an inner tray where a rigid box holds unwrapped food.
- Sustainability
- Board and paper recycle together. Magnets, ribbon and foam come out first, and the spec says which the box has.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build rigid packaging mailers on
A rigid box is two materials: the grayboard that holds the shape and the paper wrapped around it. The board decides the feel; the wrap decides everything a customer sees and touches.
Grayboard 1.2–1.5 mm
The light rigid box: jewelry, small cases, card boxes. Heavy in the hand for its size without thick walls on a small cavity.
1.2–1.5 mmGrayboard 2–3 mm
The full rigid box. Resists crushing, bends poorly — thickness is chosen from box size so a wide lid does not sag.
2–3 mmArt paper wrap
Printed coated paper, matte or gloss laminated. Full color, photographs, any design. The most flexible wrap and the least tactile.
128–157gsmSoft-touch wrap
A velvet-feel laminate over printed paper. Reads expensive, shows fingerprints on white, and scuffs at the corners before anywhere else.
128–157gsm laminatedLinen and textured wrap
Texture woven into the paper, so it cannot scuff off. Takes foil and deboss beautifully; breaks up a solid print.
120–140gsmLeather-grain and specialty
Embossed grain papers, metallics and colored stocks. One color and a foil mark, not a photograph.
120–160gsmFlocked and velvet liners
A short-fiber or woven pile for the interior and the insert. Holds a product without marking it and sets the color the piece is seen against.
Applied to board or foamMagnets and hardware
Neodymium magnets under the wrap, ribbon pulls, and hinges built from the wrap itself. Each is a line on the quote.
Per closureNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
On a rigid box the wrap is the finish, and the corners are where it is judged.
Soft-touch wrap
Velvet in the hand. The category default, and it scuffs at the corners first.
Linen and laid
Texture woven into the paper; hides marks and cannot rub off.
Hot foil
Stamped into the wrap. Small block, cheap die, large effect on a lid.
Blind deboss
Shape with no ink. On a textured wrap it is the quietest premium mark there is.
Spot UV on matte
A gloss shape on a matte field; a pattern that only shows at an angle.
Colored liner
A wrap on the inside face, seen for a second as the lid lifts. The cheapest thing that changes an opening.
Leather-grain
Embossed grain paper. One color and a foil mark, never a photograph.
Ribbon and hardware
A pull under the product, magnets under the wrap, a hinge built from the paper.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a rigid box, where the wrap is part of the wall: rigid packaging mailers
A rigid box is built up rather than folded, so the internal size is set first and the board and wrap are added outside it. The lid is then made to fit the base, and that fit is the thing people judge.
- Internal dimensions
- The product plus its insert, at the widest point. Everything else is built outward from this number.
- Wall build-up
- Each wall is the grayboard plus the wrap on both faces — roughly 2.5 mm on a 2 mm board. A small box gains noticeably in outside size.
- Lid clearance
- A few tenths of a millimeter. Set on a plain sample: a slow, air-cushioned lift, not a lid that drops off or has to be prised.
- Insert depth
- The tallest item plus 2 mm. On a two-layer box, this sets the total height and the ribbon lift.
- Humidity
- Board takes up moisture and a lid set snug in a dry factory can bind in a damp shop. We allow for the delivery market.
- Tolerance
- Plus or minus 0.5 mm on a rigid box, tighter than folding board because nothing springs back.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Rigid Packaging Mailers in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about rigid packaging mailers? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
Can a rigid packaging mailer be posted without an outer box?
It can, with the label on a band or sleeve rather than the wrap, but the corners will show wear. For premium products we recommend an outer.
Which wrap hides scuffs best on a rigid packaging mailer?
Textured or plain matte paper. Soft-touch and dark gloss show rub marks first.
Will the magnetic flap on a rigid mailer open in transit?
The magnets hold against normal handling, but a hard knock can lift the flap. A small seal sticker across the edge prevents it.
What insert goes in a rigid packaging mailer?
A wrapped card tray, a foam or EVA cut, or a paperboard platform, chosen so the product cannot touch the walls when shaken.
Can a rigid packaging mailer have a window?
Yes, a window in the lid with clear film behind it. That box should travel inside an outer so the film is not scratched.
Do you supply the outer shipper for a rigid mailer?
Yes, sized so the rigid box sits without play, printed or plain.
Do rigid packaging mailers arrive flat?
No, they arrive assembled. If space is the issue, a collapsible rigid box ships flat.
Can the inside of the flap on a rigid mailer be printed?
Yes. The inside of the flap is the first surface seen when it opens, so a message or pattern there is common.
Can a ribbon pull be added to a rigid packaging mailer?
Yes, set into the front edge of the flap so it can be opened without fingernails against the magnet.
Are rigid packaging mailers heavier to post than corrugated mailers?
Yes. Grayboard weighs more than flute, so a sample on your scale before you set shipping prices is worthwhile.
How many rigid packaging mailers can we order?
From 100 per size; the outer shipper is quoted with them so both arrive together.
Same range
