Stay-Flat Protection. Bend-Proof Shipping.
Extra-thick, bend-resistant rigid chipboard mailers for safe document and art print shipping.
Custom Rigid Mailers, often referred to as stay-flat mailers or photo envelopes, are heavy-duty flat shipping envelopes engineered specifically to protect thin, bendable items from creasing, fold lines, and corner damage. Ideal for art galleries, print shops, photographers, law firms, and e-commerce stores shipping certificates or flat goods, these mailers provide absolute structural rigidity.
Manufactured from heavy-duty 28pt to 36pt multi-ply recycled paperboard, our rigid mailers maintain a flat profile under significant bending and crushing forces. They are available in natural organic brown kraft or clay-coated white finishes. Equipped with a permanent peel-and-seal strip and an integrated perforated pull-tab tear strip, they provide both maximum transit security and a premium, easy-open unboxing experience for your customers.
Learn more in our [Complete Guide to Custom Rigid Mailers](/blog/b2b-guide-to-rigid-mailers).
See how businesses across different sectors use this packaging
Choose materials, printing, and finishing options
Durable and cost-effective for everyday packaging needs
Natural, eco-friendly look with rustic appeal
Extra protection and strength for shipping
Thick chipboard for luxury presentation
Post-consumer recycled content with smooth surface
Bright white surface ideal for vibrant printing
Thin corrugated material with compact profile
Textured and coated papers for unique finishes
From concept to delivery in 4 simple steps
Share your requirements and get a detailed quote within 15 minutes during working hours. Our team reviews every project.
Receive a digital 3D mockup. Request unlimited revisions until you're 100% satisfied.
Your packaging enters production. Track progress through your dashboard in real-time.
Free shipping to your door. Standard delivery in 7-14 business days. Need it faster? Rush production delivers in 3-7 business days.
We offer sustainable alternatives for Rigid Mailers that don't compromise on quality. Choose eco-friendly materials and printing options to reduce your environmental impact.
100% Recyclable
Made from recyclable materials
FSC Certified Options
Responsibly sourced materials
Soy-Based Inks
Eco-friendly printing
Carbon Neutral
Offset shipping available
Complete technical specifications for Rigid Mailers
| finish types | Natural Kraft Matte, Clay-Coated White, Premium Textured, Soft-Touch Matte |
| storage reqs | Store flat in dry conditions at 50°F-90°F (10°C-32°C); keep away from high humidity and damp areas |
| print quality | High-definition digital printing or flexographic print up to 400 DPI |
| assembly style | Center-seam rigid envelope with bottom fold, side-seam welds, and top adhesive flap |
| eco credentials | Made with up to 100% recycled paperboard, 100% recyclable |
| weight capacity | High structural rigidity prevents puncture and crushing under stacking pressure |
| material thickness | Heavyweight chipboard: 28pt (point) - 36pt (0.028" - 0.036" thickness) |
| production location | Printed and converted in the United States |
Experience the future of custom packaging with our AI-powered platform
Transform your ideas into print-ready packaging designs in minutes, not weeks. Our AI understands packaging constraints, bleed areas, and dieline requirements.
Get instant, expert recommendations tailored to your product. Our AI analyzes your requirements and suggests optimal materials, sizes, and finishes.
Real-time pricing in seconds
Start from just 250 units
7-14 day turnaround
Expert designers included
Worldwide delivery
100% satisfaction
Everything you need to know about Rigid Mailers. Can't find the answer you're looking for? Chat with our AI consultant.
Our AI packaging consultant can answer your specific questions and help you choose the perfect configuration.
Chat with AI ExpertOur packaging experts are available Monday-Friday, 9am-6pm.
