Made to your size- 100 boxes
- Custom sizes & styles
- Free dieline support
- Quality print options
- Proof before production
- 8–12 business day production
Rigid mailer boxes take the familiar mailer shape - a base with a hinged, tucking lid - and build it from thick wrapped greyboard instead of corrugated. The result opens like a mailer but feels like a gift box. They are used for PR kits, influencer send-outs and premium subscription boxes, usually shipped inside an outer carton.
A mailer that feels like a gift
Custom Rigid Mailer Boxes
✓Clear proofing before productionSee our process
Get a free quote
Tell us what you are packing and we’ll reply with practical options.
Product features
Built around the jobWrapped rigid board
Printed inside and out
Insert-ready
Arrives fully made up
Magnet or ribbon closure add-on
Kraft wrap with white print
Seal sticker on the front
Specifications made for your product.
Technical snapshotEvery final specification is confirmed against product weight, packing method, print coverage, route, and order volume.
View artwork preparation guide- SKU
- bm-1051
- Dimensions
- Custom-made around the product and packing workflow
- Materials
- Greyboard wrapped in printed paper, Kraft-wrapped greyboard, Specialty papers
- Printing
- CMYK, Pantone, white ink, or unprinted
- Finishes
- Matte, gloss, soft-touch, foil, embossing, spot UV
- Quantities
- Starting at 100 on selected configurations
- Proofing
- Dieline and digital proof
Mailer shape, gift box feel.
Artwork and materialsArtwork wraps the outside, the hinged lid and the inside, where the unboxing happens. A printed inside lid gives PR kits and send-outs their reveal. Our packaging guides cover sizing, materials, print, and cost in more depth.
Outside, lid and inside print
We set your artwork on the outer wrap, the tuck lid and the inside panels. The inside lid carries a welcome message or campaign art, and we place any seal sticker on the front so it frames the logo.
Explore print and finishesPrinted, kraft or specialty wraps
Printed wraps give bold full colour, kraft wraps give a natural look that suits dark ink or white underprint, and specialty papers add texture. A coloured inside gives contrast against a simple outside.
Explore material decisionsChoose your box
Tell us the items going inside, their sizes, and how the boxes will be shipped.
Request a quote
We recommend the size, wrap, closure and insert that suit your kit and send-out.
Finalize the order
Confirm the size, papers, closure, insert, print areas and delivery details.
Build the dieline
We draw the box around your items, with the insert and tuck lid set for a snug close.
Approve the proof
Check the outside, inside lid, insert and any seal sticker on the digital proof.
Roll on production
We make and wrap your boxes fully set up, check each lid, and pack them for delivery.
Best for
PR and influencer kitsPremium subscriptionsCorporate giftsProduct launchesWhat changes the price.
Cost factorsEvery project is quoted individually. These are the choices that move the price on almost every order.
- Board and wrap
- Rigid board and wrapping cost more than corrugated, and the box is assembled by hand.
- Inside print
- Printing the inside means wrapping the inside with printed paper as well.
- Inserts
- A fitted insert to hold kit items is a separate part.
- Shipping
- Rigid mailers ship assembled and usually need an outer carton, which adds to the cost per order.
Buyer guidance
Choosing this format
Rigid mailer or corrugated mailer?
Corrugated mailers are made to travel; rigid mailers are made to impress, and usually travel inside another box.
A corrugated mailer ships on its own, folds flat and costs little. A rigid mailer is thicker, heavier and finished like a gift box, so it scuffs if sent bare through a courier network.
Choose rigid when the opening moment is the point - a PR kit, a launch, a high-value subscription - and corrugated for everyday orders.
- Corrugated: ships alone, low cost
- Rigid: premium, ships in an outer
- Same opening shape
Designing the inside
The inside is what the recipient films and photographs, so plan it as carefully as the lid.
A printed inside lid with a message, a coloured lining, and an insert that holds each item in its place turn the opening into a reveal. Leave room for a card or leaflet on top of the insert.
We show the inside print and the insert together on the digital proof, so you see the reveal before anything is made.
Sending rigid mailers safely
Pack them in a plain shipping box with a little void fill, so the wrap and corners arrive unmarked.
Rigid board resists crushing well but the wrap paper marks easily. An outer carton protects it and carries the shipping label, so nothing is stuck on the printed box itself.
Related packaging formats
Compare your options
Mailer Boxes
Sturdy, self-locking corrugated mailers built for memorable deliveries.
Explore box style
Collapsible Rigid Boxes
Rigid boxes that fold flat for shipping and storage, then snap up firm at packing.
Explore box style
Welcome Kit Boxes
Branded boxes that hold several items together for new staff, clients or members.
Explore box styleQuestions about rigid mailer boxes.
Box style FAQsWe’ll confirm the exact details that apply to your structure and volume.
Read all frequently asked questionsHow are rigid mailer boxes delivered?+
Fully made, so they are ready to pack the moment they arrive, with no folding or taping. Because they come assembled, they take more storage space than flat corrugated mailers, so it helps to plan shelf space for your order. If space is tight, a collapsible rigid box with a flap lid gives a similar look and arrives flat.
How does a rigid mailer box stay closed?+
With a tuck flap at the front that slides inside the base and is held by the friction of the thick board. We size the flap to the box, so it closes firmly but opens without a struggle, even when the box is full. If you want a firmer close or a visible seal, we can add magnets, a ribbon tie or a seal sticker.
How do you size a rigid mailer box for a PR kit with several items?+
Lay out every item, including cards, tissue and any leaflet, and send us the footprint and the height of the tallest piece. We size the inside to that layout with a little room, then add the depth of any insert under the products. We also allow for the tuck flap at the front, because rigid board does not flex like corrugated and the lid needs to close flat.
Can a rigid mailer box have a kraft finish?+
Yes. We can wrap the greyboard in kraft paper for a natural, understated look that suits a one-colour logo, often with a printed or coloured inside for contrast. Dark inks print best on kraft, while light colours look weak on the brown surface, so for a white logo we use foil or a white underprint. Kraft also hides small scuffs better than a smooth bright paper.
What is the difference between a rigid mailer box and a magnetic closure box?+
Both have a lid hinged to the base. A rigid mailer's lid tucks into the front of the base, like a corrugated mailer, while our magnetic boxes have a flap that folds down over the front and is held by hidden magnets. The tuck gives a familiar mailer opening; the magnetic flap feels smoother and more like a gift box. We make both, so choose by the opening you want your customer to see.
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