Rigid Mailers are heavyweight setup-style mailing boxes built to protect premium products in transit while delivering a branded unboxing on arrival. Each one is made from thick rigid board wrapped in printed paper and custom-printed to your design.
The rigid walls resist crushing and bending far better than a folding mailer, so high-value items reach customers intact and looking sharp. That durability makes them a fit for direct-to-consumer brands shipping electronics, apparel, or fragile keepsakes, where the box itself becomes part of the brand experience.
Materials & Specifications
- Material: Rigid chipboard wrapped in printed paper
- Thickness: 1.5 to 2.5mm rigid board
- Printing: Full-color CMYK, inside and outside
- Finishing options: Soft-touch lamination, foil stamp, emboss or deboss, spot UV, foam or EVA insert
- Paper: FSC-certified option
Best Used For
- Direct-to-consumer shipments of premium goods
- Electronics, apparel, and fragile collectibles
- Subscription boxes that ship and present in one piece
- Limited drops where the mailer doubles as a keepsake box
Printing & Finishing
Print Rigid Mailers in full-color CMYK on the outside, then carry your brand to the inside walls so the unboxing keeps going. Add soft-touch lamination for a premium grip, foil stamping for a metallic mark, emboss or deboss for texture, and a foam insert to lock the product during shipping.
Why Order from Teal
Teal is a US-based packaging supplier. Specialty rigid boxes start at a 100-unit minimum, and every order includes free design help, free US shipping, and full-color CMYK printing. Run rush service (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs) or standard production from about 7 business days after proof approval, add the FSC-certified paper option, and Order a sample kit ($50, credited to your first order).
FAQ
What's the minimum order quantity? The standard MOQ is 50 units. As a specialty rigid box, rigid mailers start at 100 units.
How long is production? Standard production runs from about 7 business days, with a rush option (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs) available.
Can I get a sample? Yes. A $50 sample kit shows the rigid build and print quality, and we credit it to your first order.
Are they recyclable? Choose the FSC-certified paper option for responsibly sourced material.
Request a free quote and we'll get back to you within 4 business hours.
Rigid Mailer Quantities for Flat Goods
Stiffness is the product. Caliper has to resist bending across the longest span, which is why a wider mailer needs heavier board than a narrow one carrying the same item. A peel and seal strip closes without tape, a tear strip controls the opening line, and a printed inner face turns the reveal into part of the brand experience.
| Mailers | Flat goods guidance |
|---|---|
| 50 | Bend trials through a real postal network. |
| 500 | A print seller or photographer through one season. |
| 1,000 | Two spans covering prints and documents alike. |
| 5,000 | Seal strip application settles into the unit figure. |
| 10,000+ | Bulk dispatch supply from about $0.44 per unit at volume. |
Delivery falls into two bands. Mailers converted here may be complete about 7 business days out, specialty imported board can stretch to about 12 weeks, both cited only as planning ranges, not guarantees. A digital proof of both faces is confirmed before the run. Send flat dimensions, contents thickness, caliper preference, seal type, and monthly dispatch count.
How to Order Rigid Mailers
Ordering custom rigid mailers is simple:
- Submit a quote request with your dimensions, quantity, and design references
- Receive quote guidance within one business day
- Send your artwork or work with our design team (free dieline + 2 revision rounds)
- Approve the digital proof and production begins
- Standard production runs from about 7 business days after proof approval; complex or high-volume orders take longer
