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Corrugated boxes are the workhorse of US e-commerce, wholesale, and retail fulfillment — the fluted, kraft-lined cartons that ship product from warehouse to doorstep without a dent. We print custom corrugated in single-wall and double-wall constructions, from branded e-commerce mailers to heavy-duty master shipping cartons, with runs starting at 100 units and no setup, plate, or die charges.
For US DTC brands, wholesalers, subscription programs, and 3PL-fulfilled businesses that ship physical product and want the outer carton to protect the goods and reinforce the brand.
About Corrugated Boxes
What corrugated is and where it fits
Corrugated is not folding-carton board — it is a fluted paper core sandwiched between two liners, engineered to absorb impact and stack under load. That makes it the right choice any time a box has to survive a fulfillment center, a delivery truck, and a doorstep drop, not just a shelf. US brands reach for corrugated for e-commerce mailers, subscription shipments, wholesale master cartons, moving and storage, and industrial or heavy retail cases. For lighter retail-only packaging — cosmetics, food cartons, small consumer goods on a shelf — see our custom paper boxes and tuck-end cartons instead.
Corrugated styles we print
- Regular slotted cartons (RSC): the classic shipping box — top and bottom flaps meet in the middle. The cheapest, most efficient format for e-commerce and warehouse shipments.
- Printed mailer boxes (roll-end tuck): the branded DTC unboxing carton, self-locking with no tape needed on the outside.
- Full-overlap and half-slotted cartons: heavy-duty variants for stacked or weighty freight.
- Die-cut corrugated: custom shapes, inserts, and dividers cut to your product.
- Master shipping cartons: larger outers that hold multiple retail units for wholesale and distribution.
Print, sizing, and structural spec
Corrugated is printed either flexo (direct on the liner — fast and durable, ideal for logos and 1-2 colors) or litho-laminated (offset-printed sheet bonded to the corrugated for full-color, retail-grade artwork). Sizing follows the product: we dieline to inside dimensions with the right allowance for board caliper so the box does not crush the product or ship air. Bursting strength (ECT or Mullen) is chosen for the weight and stacking load — 32 ECT covers most DTC shipments, 44 ECT and double-wall for heavier or long-haul freight.
Ordering, MOQ, and lead time
Minimum order is 100 units for standard printed corrugated. Standard production is 7–10 business days after artwork approval; rush 3–5 is available on request. Every order includes a free 3D digital mockup, a physical sample on request (refunded on your first order), free dieline support, and free US shipping. Per-unit price improves at 250, 500, and 1,000+ — request a tiered quote for exact price breaks.
Sustainable corrugated
Corrugated is one of the most-recycled packaging materials in the US waste stream. We can spec recycled-content stocks, water-based inks, and right-sized dielines that ship less air and less material per order — the fastest way to cut both freight cost and carbon per shipment.
Why US brands choose us for corrugated boxes
Custom Box Printing manufactures corrugated boxes from our US production facility, with free standard shipping anywhere in the contiguous United States and a 7–10 business day turnaround. We've printed corrugated boxes for solo founders launching their first product line, growing direct-to-consumer brands placing 5,000-unit runs, and established retail brands with 50,000+ unit production schedules — and we treat all three the same: low MOQs (100-unit runs), free design support, no setup or die-plate charges, and a 3D digital mockup before anything goes to press.
Every corrugated boxes order includes free in-house dieline and artwork support — our US-based designers will polish your existing files, or build a custom dieline from scratch to fit your exact product dimensions. We send you a 3D mockup to confirm look and proportions before production. For color-critical work, request a physical sample free — let’s talk about a customized sample so you can confirm the look before a full run.
Materials, print, and finish options
Corrugated is spec'd by flute and wall. E-flute (1.5mm) gives a smooth print surface for retail-facing shipping mailers; B-flute (3mm) is the everyday DTC standard; C-flute (4mm) is the classic shipping-case flute for heavier goods; and BC double-wall stacks two flutes for master cartons and freight-ready loads. We line with white or kraft top-sheet depending on whether print clarity or the natural brown look matters more, and we can spec 32 ECT for typical shipments through 44 ECT for heavy or stacked freight.
Available finishes include:
- Lamination: Gloss, matte, soft-touch, or velvet finish for a premium hand-feel.
- Foil stamping: Gold, silver, copper, or custom foil colors for high-visibility brand marks.
- Embossing & debossing: Tactile raised or recessed surface effects on logo or key artwork.
- Spot UV: Selective gloss coating that creates contrast against matte areas.
- Eco-friendly options: Recycled kraft, widely recyclable paperboard and water-based inks.
- Compliance: soy-based inks; child-resistant-style constructions for CBD/cannabis on request.
If you're not sure which combination will work best for your corrugated boxes, mention it in your quote request — our team will recommend the right material, print spec, and finish based on your product, budget, and brand positioning.
How to order your corrugated boxes
- Request a quote — use the "Get Free Quote" button on this page, or call (855) 792-3890 (toll free). Tell us your box style, dimensions, quantity, material preferences, and any deadline.
- We respond within 1 business day with pricing, lead times, and material recommendations. No pressure, no commitment.
- Free design + 3D mockup — we build your dieline (or polish your existing artwork) and send you a 3D digital mockup to approve.
- Optional physical sample — request a custom sample (refunded on your first order) to hold the real box in hand — let’s talk it through.
- Production & free US shipping — once you approve, we print and ship in 7–10 business days, free anywhere in the United States.
Corrugated Boxes Weight and Price Calculator
Get an instant weight estimate (per box, total order, and shipping dimensional weight) and a per-unit price estimate for your corrugated boxes. Enter dimensions in inches or centimeters — the calculator converts automatically. For a firm quote, request a free quote.
Pick your box material
Choose the stock first — each calculator below has its own length × width × height inputs.
Part 1 Weight calculator
Finished box weight and the dimensional weight US carriers (USPS, UPS, FedEx) use for shipping.
Dim weight uses the US domestic divisor of 166 (L × W × H ÷ 166 in pounds). Carriers bill the greater of actual or dimensional weight.
Part 2 Price calculator
Instant per-unit and total estimate in the US-market range for the spec below. Firm pricing requires your artwork and exact spec.
US-market estimate based on 2026 rates. Exact pricing depends on artwork, exact stock, Pantone requirements, and finish combinations. No setup, die, or plate fees at any quantity.
Corrugated Boxes — Frequently Asked Questions
