Stay-Flat Protection. Bend-Proof Shipping.
Extra-thick, bend-resistant rigid chipboard mailers for safe document and art print shipping.
Custom Rigid Mailers are the ultimate flat shipping envelopes designed to prevent bending, creasing, and corner damage for important documents, art prints, photos, certificates, and flat collectibles. Constructed from heavy-duty, multi-ply recycled chipboard or extra-thick clay-coated board, these rigid packaging envelopes feature a secure self-sealing adhesive strip and an easy-open tear tab.
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
Rigid mailers ship photographic prints, fine art reproductions, and limited edition prints without bending. Corner protection and stay-flat construction prevent damage.
Legal documents, diplomas, certificates, and contracts ship flat and protected in rigid mailers. Tamper-evident sealing provides chain-of-custody assurance.
Dual-seal rigid mailers with built-in return strip simplify customer returns for flat items. Pre-printed return address and postage simplify the return process.
Rigid mailers protect vinyl records, CDs, and Blu-ray discs during postal shipment. Padded options provide 3G impact cushioning for disc media formats.
Large-format rigid mailers ship calendars, posters, and large-format prints flat. Eliminates rolling and tube shipping for items that must arrive perfectly flat.
Premium rigid mailers deliver property brochures, lookbooks, and marketing materials. Foil-stamped branding creates an upscale first impression at the mailbox.
Choose materials, printing, and finishing options
2mm greyboard rigid mailer with stay-flat construction preventing bending. Protects documents, photos, and prints up to 13x19 inches during postal transit.
B-flute micro-corrugated board with 3mm thickness and 200 ECT crush resistance. Rigid structure resists postal sorting machine compression on flat items.
Natural brown E-flute corrugated at 1.5mm thickness for lightweight rigidity. Ships flat and assembles into rigid format reducing warehouse storage requirements.
Paper honeycomb core between kraft facings at 5mm total thickness. Ultra-lightweight rigid construction weighing 50% less than solid chipboard at equivalent rigidity.
100% post-consumer recycled greyboard with kraft wrapper exterior. Maintains bend resistance at 2.5mm thickness while eliminating virgin material consumption.
Clay-coated 2mm rigid board with smooth white printable surface. Accepts full CMYK offset printing directly without wrapper paper for cost-effective branding.
Chipboard mailer with integrated foam or pulp cushioning layer. Provides 3G impact protection for photography prints, glass, and thin electronics.
Rigid polyurethane foam board at 3mm thickness with paper facings. Extreme lightweight rigidity and thermal insulation for temperature-sensitive flat shipments.
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.
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Start from just 250 units
7-14 day turnaround
Expert designers included
Worldwide delivery
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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.
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