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 manufacturer. 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 5-day rush or 7-business-day standard production, add the FSC-certified paper option, and Order a free sample kit (just $19.99 shipping, 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 7 business days, with a 5-day rush option available.
Can I get a sample? Yes. A free sample kit (just $19.99 shipping) 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.
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 takes 7 business days after proof approval; complex or high-volume orders may require 10-14 business days
