Flat Pack Postal Boxes
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Custom flat pack postal boxes cut to USPS and carrier flat-rate dimensions, shipped flat to save storage space and reduce postage costs.
$0.74
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 postal boxes are cut to carrier-compliant dimensions so businesses can hit flat-rate and dimensional-weight limits every time, while shipping to your dock unfolded to save storage space until an order goes out. Crat Packaging builds these corrugated mailers to match USPS and common carrier size brackets, printed with your brand.
Flat Pack Postal Boxes Specifications
| Box Style | Flat-pack corrugated mailer, carrier-compliant dimensions |
|---|---|
| Material | E-flute or B-flute corrugated, kraft or white liner |
| Assembly | Tool-free fold-and-lock construction |
| Best For | USPS and carrier flat-rate shipping, postal mailers |
| Print Options | Full-color offset with logo, barcode, and address panels |
| Order Volume/MOQ | Low minimums for small shippers, tiered bulk pricing |
| Shipping | Ships flat nationwide, freight discounts on pallets |
Why Businesses Choose This Format
Postal carriers charge by size bracket as much as weight, and a box a fraction of an inch too large can push a shipment into a higher-cost tier. These are engineered to common flat-rate and dimensional-weight brackets, and because they ship unfolded, a shipping desk holds months of correctly sized stock without a full room dedicated to storage. Small shippers, subscription companies, e-commerce sellers, and mailrooms watching per-package cost all rely on the format.
Eco-Friendly Postal 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 at no added cost.
Sizing and Print Options
We cut to standard postal brackets or custom dimensions, with full-color branding, barcode zones, and address panels available. Small shippers can start with a single-color stamp and scale to premium branded printing.
Comparing Flat Pack Styles
This format focuses on strict carrier size compliance. For a standard, ready-made postal carton, see flat postal boxes. For bulk e-commerce fulfillment beyond postal limits, see flat pack shipping boxes, or for office mail see flat pack mailing boxes. You can also browse extra large postal boxes.
Why Order From Crat Packaging
- Cut to standard postal and carrier size brackets
- Low minimum order quantities for small shippers
- Recyclable, FSC-certified board with eco-conscious inks
- Fast production and nationwide freight shipping
- Free digital proof before printing
- Dedicated account support from quote to delivery
How to Order
- Send us your target carrier and size bracket
- Choose flute type, print colors, and finish
- Approve a free digital proof
- Receive flat-packed cartons ready to ship
Frequently Asked Questions
How is this different from flat postal boxes?
This is the ships-flat, tool-free-assembly version built for storage efficiency, while flat postal boxes are our standard, ready-made postal carton.
Will these meet USPS flat-rate size limits?
Yes, we cut dimensions to common flat-rate and dimensional-weight brackets so shipments qualify for the intended rate.
How is this different from flat pack shipping boxes?
This style is sized for postal compliance, while flat pack shipping boxes suit bulk parcel carrier fulfillment beyond postal limits.
What is the minimum order quantity?
MOQs stay low for small shippers and scale down in price as volume grows.
Can I print my logo and barcode area?
Yes, from a one-color stamp to full-color branded printing with dedicated barcode zones.
How fast is production?
Standard runs ship within one to two weeks of proof approval, with rush options available.
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