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Corrugated Boxes

Custom-printed corrugated boxes for US direct-to-consumer and retail brands — runs from 100 units, free 3D mockup, free US shipping.

Corrugated Boxes — custom printed packaging by Custom Box Printing

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Low MOQ (100 cardstock / 50 rigid) · free design + 3D mockup · reply in 1 business day

Corrugated Boxes
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🔒 custom sample (refunded on your first order) · free US shipping

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FREE Shipping All Across the USA Low MOQs, no hidden freight fees — to all 50 states.

FREE 3D Design Tool Build & preview your box online before you order.

FREE Design Support Our US team perfects your artwork & 3D mockup.

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 100% recycled content, FSC-certified 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-safe 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, FSC-certified stocks, water-based inks, recyclable rigid constructions.
  • Compliance: FDA food-safe inks; certified child-resistant constructions for CBD/cannabis where required.

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

  1. 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.
  2. We respond within 1 business day with pricing, lead times, and material recommendations. No pressure, no commitment.
  3. Free design + 3D mockup — we build your dieline (or polish your existing artwork) and send you a 3D digital mockup to approve.
  4. Optional physical sample — request a custom sample (refunded on your first order) to hold the real box in hand — let’s talk it through.
  5. Production & free US shipping — once you approve, we print and ship in 7–10 business days, free anywhere in the United States.

Corrugated Boxes — Frequently Asked Questions

The minimum order for corrugated boxes is 100 units. Start with a 100-unit run to test a new SKU or a redesign, or scale into the thousands and tens of thousands for full retail — per-unit pricing improves as your volume grows.

Yes — standard shipping is free anywhere in the contiguous United States on every order. Rush production (3–5 business days) and expedited shipping are available on request for an additional fee.

Standard production turnaround is 7–10 business days from artwork approval. We confirm your dieline, send a 3D digital mockup, and start production once you approve. Rush orders typically ship in 3–5 business days.

Yes. Physical samples cost $50 upfront and are refunded when you place your first order — just ask and we’ll sort out a customized sample for your box, no obligation. We also send a free 3D digital mockup with every quote.

Yes — we stock recycled kraft, FSC-certified paperboards, water-based and soy-based inks, and recyclable corrugated and rigid stocks. Mention "eco" in your quote request and we'll recommend the best material for your product.

Full-color CMYK offset printing with Pantone spot matching is standard. Premium finishes include gloss / matte lamination, soft-touch, spot UV, embossing, debossing, and gold or silver foil stamping. Custom die-cut shapes are available on request.

We accept print-ready PDF, AI, EPS, and PSD files at 300 DPI in CMYK color mode with a 0.125" bleed. If you don't have a print-ready file, our in-house design team will build your dieline and prep artwork for free — just send us a logo and any brand references.

No — there are no setup, plate, die, or tooling fees on any order, at any quantity. The price you're quoted covers full production, custom dielines, printing, finishing, and free US shipping. No surprise line items.

Mailer boxes are corrugated boxes designed for shipping with a self-locking front. Rigid boxes are premium thick-walled non-collapsing boxes used for luxury packaging. Folding cartons are lightweight paperboard boxes that ship flat and assemble at point of use. Corrugated boxes have a fluted middle layer for added protection during shipping.

Yes — many brands run a mailer + folding-carton combo in a single order: the mailer for e-commerce shipping and a matching folding carton inside for a branded unboxing. We coordinate artwork, stock, and finishing so both structures ship together and read as one system.

We can produce corrugated shipping boxes up to roughly 30×20×20" as standard, with larger custom sizes available on request. Folding cartons and rigid boxes are typically smaller — up to about 18×14" flat — depending on stock weight and structure.

Yes — we design paperboard inserts, corrugated dividers, foam inserts, and molded pulp trays to securely hold bottles, jars, palettes, and multi-piece retail sets. Inserts ship pre-cut and pre-scored so your fulfillment team can assemble at pack-out.

In the trade, 'cardboard' usually means single-layer paperboard (like a cereal box or folding carton). 'Corrugated' has a fluted middle layer between two liners, which is why it absorbs impact and stacks under load. Corrugated is what you want for shipping; paperboard is for retail folding cartons.

Yes. For full-color, photographic, or edge-to-edge artwork we litho-laminate — offset-print a top sheet and bond it to the corrugated board. For 1-4 color logo and text work, direct flexo print on kraft or white liner is faster and more cost-effective.

Tell us the product weight, whether the box ships alone or inside a master carton, and whether it will be stacked in transit. We'll recommend a flute (E, B, C, or BC double-wall) and ECT rating that survives the shipping lane without over-spending on board.
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