Flat Pack Mailing Boxes
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Custom flat pack mailing boxes that ship flat to save storage space, print with your brand, and keep postage costs down for growing mailrooms.
$0.73
UNLIMITED CUSTOMIZATION OPTIONS
A printing technique employing a plate to transfer designs onto paper. Ideal for extensive print jobs.
Plate-free digital printing transfers designs electronically, cost-effective for short runs.
Screen printing is a method using a mesh screen and stencil to transfer ink onto a substrate.
Quick-drying printing technique utilizing ultraviolet lights for ink curing, yielding a glossy finish.
Consisting of water-based pigments, Ensures top-notch color output with a 100% eco-friendly profile.
Fluorescent inks are vibrant, UV-reactive pigments that emit vivid colors under ultraviolet light.
Generate pure colors using specific ink formulas to consistently & precisely reproduce color in printing.
Produce metallic colors through precise ink formulations to replicate color in printing.
Premium bleached white paperboard, specially coated on one side to enhance printing & finishing.
Bleached white paperboard, coated on both sides to achieve superior printing quality and finishes.
Top-notch textured paper, perfect for adding a touch of style when wrapping up durable boxes.
A unique paper material showcasing a shiny or matte metallic laminated surface.
Bleached kraft paper crafted from a blend of new and recycled pulp, coated on both sides for optimal printing.
Kraft paper produced from a combination of new and recycled paper pulp, with coating on both sides for printing purposes.
Kraft paper dyed black, manufactured from a blend of new and recycled pulp, and coated on both sides for printing applications.
Crafted from recycled grey chipboard cardboard, also known as uncoated recycled paperboard, ideal for luxury rigid boxes.
Unique paper material showcasing a holographic laminated surface in either glossy or matte finish.
Grey chipboard, one-sided white cardboard with a smooth, printable surface, ideal for luxury rigid boxes.
Gloss lamination enhances visual appeal by applying a shiny finish, and protecting printed materials.
Matte lamination offers a non-reflective finish, providing elegant appearance to printed materials.
Made with a smooth lamination that feels like touching a peach, can choose between a satin or matte.
A UV coating is applied to a specific area and then cured using ultraviolet light to make it sturdy.
A transparent coating is applied using the CMYK printing technique, and it comes in gloss, satin, or matte.
A fast-drying coating that undergoes curing through ultraviolet light is offered in both gloss and matte.
In a printing method, dies are pressed onto the back of the material to create a raised motif.
A printing technique that involves pressing dies onto the front of the material to create a raised motif.
In foil relief printing, foil is transferred at high temperatures, often employing multiple colors.
Craft a die-cut shape with a plastic film layer, revealing a window to showcase the product inside.
We recommend the ideal material and add-ons like lamination, foiling, embossing UV, etc.
Get Free Design Support with your box 3d Renders or Send Your Design File for Printing.
Upon design approval, we’ll print and conduct quality checks before shipping the boxes to you.
Technical Specifications
| Dimensions | Available in Custom Sizes |
| Printing | CMYK, Pantone Color, Full Color & No Printing |
| Paper Stock | Eco-Friendly Kraft, Corrugated Cardboard & Premium Rigid Stock |
| Coating | Semi-Gloss AQ, Gloss UV, Matte UV & Spot UV |
| Default Process | Die Cutting, Gluing, Scoring, Perforating |
| Custom Options | Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink |
| Proof | Digital Proof, 3D Mock-Up |
| Shipping | Shipped FLAT (Free Shipping Across USA & Canada) |
| Help | For further inquiries and Quotes, contact us or email at sales@cratpackaging.com |
Flat pack mailing boxes give growing businesses a fast way to control postage costs and back-office storage, arriving unfolded so a pallet takes a fraction of the warehouse space until an order ships. Crat Packaging builds these corrugated mailers to custom sizes and prints them with your brand.
Flat Pack Mailing Boxes Specifications
| Box Style | Flat-pack corrugated mailer, tuck-top or self-locking base |
|---|---|
| Material | E-flute or B-flute corrugated, kraft or white liner |
| Assembly | Tool-free fold-and-lock, ready in seconds |
| Best For | Office mailrooms, subscription boxes, small parcel shipments |
| Print Options | 1 to 4-color flexo or full-color offset with logo and return address |
| Order Volume/MOQ | Low minimums for startups, tiered pricing for bulk programs |
| Shipping | Ships flat nationwide, freight discounts on pallet orders |
Why Businesses Choose This Format
Companies that mail invoices, samples, or small products on a regular schedule need a box that will not eat up shelf space between mailings. Because these cartons ship unfolded, a mailroom stores months of supply in a single closet, then folds boxes into shape as orders arrive. Corporate mailrooms, subscription companies, law firms, medical offices, and online sellers all rely on the format when volume changes week to week and floor space is limited.
Eco-Friendly Mailing Packaging
A 2025 McKinsey survey found that over 60% of U.S. consumers pick green packaging when they have the choice. Crat Packaging builds these mailers from recyclable, FSC-certified corrugated board with soy-based inks.
Custom Sizing and Print Options
Sizes run from small parts mailers to document-sized cartons, cut to exact dimensions so contents stay snug. Add a one-color return address stamp for a simple job, or go full-color with your logo for a customer-facing shipment.
Comparing Flat Pack Styles
This style suits routine, lower-volume office mailing rather than e-commerce fulfillment. For strict carrier dimensions, see flat pack postal boxes; for household moves, see flat pack packing boxes. For rigid, ready-to-use mailers, browse bespoke mailing boxes or square mailing boxes.
Why Order From Crat Packaging
- Custom corrugated cartons cut to your exact dimensions
- Low minimum order quantities for growing mailrooms
- Recyclable, FSC-certified board with eco-conscious inks
- Fast production turnaround and nationwide freight shipping
- Free design proof before printing
- Dedicated account support from quote to delivery
How to Order
- Send us your item dimensions and monthly volume
- Choose flute type, print colors, and finish
- Approve a free digital proof of your design
- Receive your flat-packed cartons ready for the mailroom
Frequently Asked Questions
How is this different from flat pack shipping boxes?
These suit documents and small parcels from an office, while flat pack shipping boxes suit bulk e-commerce fulfillment.
Can these meet postal size limits?
We cut to common carrier limits; for strict flat-rate compliance see our flat pack postal boxes.
What is the minimum order quantity for flat pack mailing boxes?
MOQs stay low for new mailrooms and scale down in price as volume grows.
How much storage space is saved?
A pallet takes roughly 80% less space than the same quantity pre-assembled.
Can I print my logo and return address?
Yes, from a one-color stamp to full-color branded printing inside and out.
How fast is production?
Standard runs ship within one to two weeks of proof approval, with rush options available.
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