Custom Mailers

Deliver your non-fragile goods in custom mailers from Shop Rigid Boxes. Our boxes feature a mailer structure with inter-locking flaps. The flaps, when tucked in, securely close the box and do not open during transit or in warehouse drop offs. We manufacture these boxes in cardstock construction that matches your product’s weight handling requirements. 

You can add tamper-evident seals on these boxes, as they act as proof that someone opened the box. Bubble and padded mailers are also available for cushioning sensitive, delicate items. For modern eco-conscious brands, we offer recyclable cardstock options as well. Our custom mailers are a top choice for ecommerce brands, apparel, home textiles, books, & cosmetics businesses. 

Send us your requirements. We will create a digital mockup of your custom mailer based on that. Once you approve the sample, we start full production that aligns with your shipping requirements. Get a free quote today!

Turnaround12–15 daysRush in 7–9
DielineFreeUnlimited revisions
ProofBefore printSample on request
ShippingFree, US-wideTracked, 50 states
4.9 / 5from 96+ brands

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    Upload Your Design

      Premium materials

      Food-grade films and foils, sourced to spec and tested before every run.

      Barrier you can trust

      Multi-layer laminates that hold back light, oxygen, moisture and odour.

      Fast turnaround

      12–15 working days as standard, with rush production in 7–9.

      Expert support

      A named specialist from dieline through to delivery, on call throughout.

      Transform Your Shipping Strategy with Versatile Benefits & Uses

      Custom mailers are specially used in e-commerce, retail, and subscription companies for safe or best shipping. They are best for shipping clothes, accessories, documents, cosmetics, & lightweight gift products. One of their most significant advantages is comfort, because they are easy to pack, seal, and ship without requiring extra materials or inserts.

      The top benefits of mailers are brand recognition, product protection, cost efficiency, and unboxing experience. Plus, these mailers help companies lower shipping costs due to their lightweight structure and also offer trustworthy security. 

      You can opt for our custom mailers in bulk to further lower the price and make it a constant supply for large-scale use. They also improve brand visibility, as you can print logos, colors, or designs on the packaging for branding. This creates a memorable unboxing experience or keeps the brand recognition. Furthermore, these mailers save your space and make it easy to store and manage large orders. Their flexible sizes provide the right fit for your product!

      Must-Have Eco-Friendly Materials & Vibrant Designs

      Custom mailers are created from premium materials such as brown kraft paper, corrugated board, or other good-quality options. Best for a sustainable brand that needs planet-friendly packaging. This brown kraft paper creates eco-friendly mailers that offer extra strength and cushioning. These materials make these boxes best suited for fragile products. Additionally, it offers water resistance properties to make the food fresh and safe during shipping.

      The personalized mailers, in terms of design, offer many possibilities. You can pick from minimal, clean designs and colorful prints that improve brand image. These printing methods allow companies to print good-quality graphics, logos, and messaging to stand out in the market. Also, the finishing options like matte & gloss layers can also improve the look or feel of the packaging. These mixtures of strong materials and attractive designs guarantee that these customized mailers protect products and also create a strong visual mark.

      Make Your Box, Your Way

      Boxes are not just for keeping things safe; they're the first thing people see when they look at your product. That's why it's important to have a box that shows off your brand. At Shop Rigid Boxes, we let you choose everything about your box. From the material and color to how it feels and opens, you're in charge.

      Our team knows a lot about boxes, and they're here to help you make the best one for your brand. And don't worry about the price; we make sure it's affordable. Want a box that truly speaks for your brand? Talk to us at Shop Rigid Boxes, and we'll help you create it.

      Customization options

      Offset Printing Offset Printing
      Digital Printing Digital Printing
      Pantone Colors Pantone Colors
      Soft Touch Lamination Soft Touch Lamination
      Spot Gloss UV Spot Gloss UV
      Hot Foil Printing Hot Foil Printing
      Blind Embossing Blind Embossing
      Window Patching Window Patching
      White Kraft White Kraft
      Natural Brown Kraft Natural Brown Kraft
      Textured Paper Textured Paper
      Grey Chipboard Grey Chipboard

      Frequently asked questions

      What are 4x6 rigid mailers used for?

      Small objects like photos, cards, and booklets are shipped using them without bending or folding.

      Why should I choose 4x6 rigid mailers instead of normal envelopes?

      They are more robust and thus, they make your products lay flat and safe on shipping.

      How can these mailers be best sealed?

      The mailers are all self-closing and there is no need to use additional tape and the flap closes fast and tight.

      Which materials make these mailers eco-friendly?

      They apply recyclable cardboard which minimizes waste and safeguard the environment.

      Do you provide design assistance?

      Yes, we have a team of design specialists who can assist you in bringing your packaging vision to life. Whether you have a design in mind or need inspiration, we're here to help!

      What are the circumstances in which rigid mailers should be used over bubble mailers?

      They are substitutes to soft, padded cushioning when you have to find strong, flat, protection of paper items.

      Can I get a sample before placing a large order?

      Yes, we provide sample boxes so you can assess the quality and design before committing to a larger order.

      Do you offer bulk discounts?

      Absolutely! The larger the quantity of your order, the more cost-effective the price per box will be. Reach out to our sales team for specific bulk discount details.

      Still have a question? We reply within 2 hours on business days. Contact our team

      Talk to a packaging expert

      Personalised recommendations and a free quote for your custom packaging.

      Request free consultation