Corrugated packaging, built around your product.
From lightweight E-flute mailers to heavy-duty shippers, every board grade and flute is engineered around your dimensions and delivery route.
Why Corrugated Boxes
Built to Ship Flat, Engineered to Protect
Corrugated boxes are the backbone of e-commerce and retail shipping — and the most versatile packaging you can specify. They ship flat to save freight, cushion products with a fluted paper core, and print beautifully inside and out. Whether you ship apparel, cosmetics, electronics, food, or industrial goods, a custom corrugated box protects your product and carries your brand from warehouse to doorstep.
Engineered From the Flute Up
Fluted Strength. Cushioning in Every Layer.
The strength of a corrugated box comes from its structure: a fluted paper medium sandwiched between two liner boards. The arch-shaped flutes trap air, absorbing shock and resisting crush — so your product arrives intact even after long-haul transit.
We precision-die-cut every box from high-quality corrugated board. The score lines are tested for clean, repeatable folding — no cracking, no misalignment, no frustration.
Printed to Impress
Full-Color Print. Premium Finishes. Your Brand, Front and Center.
Print on the exterior, interior, or both. We apply full CMYK offset or digital printing on kraft, white, or coated corrugated surfaces. Add soft-touch lamination for a velvet feel, spot UV for selective gloss, or foil stamping for metallic accents.
Your logo, pattern, or full-bleed artwork — printed at 300 DPI across every panel. Pantone matching available for brand color consistency. The inside of the lid is prime real estate for a thank-you message or product story.
Corrugated Box Styles
Choose the Right Corrugated Box for Your Product
From everyday shipping cartons to retail-ready displays — every style ships flat and is fully customizable in size, board grade, print, and finish. Not sure which fits? Tell us your product and we’ll recommend.
RSC Shipping Carton
The global standard for shipping. Four flaps meet in the middle and seal with tape or staples — the most cost-effective corrugated box for e-commerce and fulfillment.
Get a Quote →Roll End Tuck Top
Rounded roll-end edges with a tuck-top closure — no tape required. A premium, sturdy shipper for apparel, gifts, and subscription products.
Get a Quote →Self-Locking Mailer
Classic airplane-style mailer with self-locking side wings. Ships flat, assembles in seconds, no tape — ideal for lightweight e-commerce goods.
Get a Quote →Reverse Tuck Box
Top and bottom flaps tuck in opposite directions. A clean, lightweight carton for cosmetics, electronics, and retail shelves.
Get a Quote →Straight Tuck Box
Both flaps tuck from the same side for fast, consistent assembly. Perfect for hanging retail packaging and point-of-sale display.
Get a Quote →Counter Display Box (PDQ)
Retail-ready display with a perforated front that tears away to reveal product on the shelf. Ships flat, sets up in seconds.
Get a Quote →Five-Panel Folder (FPF)
A single continuous board that wraps around the product with one glued seam. Excellent for long, narrow, or flat items.
Get a Quote →Heavy-Duty Tri-Wall
Multi-wall (triple-flute) board built for heavy, industrial, or export shipments. Replaces wooden crates at a fraction of the weight.
Get a Quote →Materials & Board Grades
From Light-Duty to Heavy-Duty — Pick Your Board
Corrugated boxes are made from a fluted paperboard core sandwiched between liner sheets. The flute grade and liner type determine weight capacity, print quality, and feel.
E-Flute Corrugated
Ultra-thin (1.2mm). Best print surface. Ideal for light products: cosmetics, jewelry, small electronics.
B-Flute Corrugated
Standard (2.5mm). Balance of strength and print quality. The go-to choice for most e-commerce boxes.
BC-Flute Double Wall
Heavy-duty (6mm). Maximum crush resistance. For heavy items: bottles, electronics, bulk orders.
A-Flute Corrugated
Thickest single-wall flute (~4.5mm). Maximum cushioning in a lightweight board — ideal for larger shipping boxes and heavier items.
Paper & Print Surfaces
Kraft (Natural Brown)
Eco-friendly, unbleached kraft liner. Best for organic, minimalist, and sustainable brands.
White Top (Coated)
White clay-coated outer liner. Bright, smooth surface for maximum color vibrancy and photo-quality print.
Kemi White Board
Premium white-top kraftliner. Semi-gloss, excellent print quality with the strength of kraft backing.
FSC-Certified Options
All board grades available FSC-certified. Fully recyclable, from responsibly managed forests.
Coatings & Finishes
Aqueous Coating
Water-based, eco-friendly. Protects print from scuffs and moisture during transit.
Gloss / Matte UV
High-gloss or non-reflective matte. Both add a protective layer and enhance shelf presence.
Soft-Touch Lamination
Velvet-like matte finish that customers cannot stop touching. Premium feel for luxury brands.
Foil Stamping / Embossing
Metallic foil accents or raised/debossed textures. Make your logo tactile and memorable.
Why PackagingSmith
Three Reasons Brands Choose Us for Corrugated Boxes
Corrugated boxes are only as good as the factory that makes them. Here’s what we do differently.
1,000-Piece MOQ
Most corrugated box factories require 3,000+ pieces. We start at 1,000, so you can launch a new product, test a design, or run seasonal packaging without overstocking.
1-3 Day Samples
Digital proof in 24 hours. Physical sample with your exact dieline in 1-3 days. Test the fit with your actual product before committing to a production run.
Free Dieline & 3D Mockup
Give us your product dimensions and artwork. We create a print-ready dieline, adjust for material thickness and fold tolerances, and send a 3D rendering — no charge.
Beyond the Box
Upgrade Your Corrugated Box Experience
Inside Print
Print a brand message, care instructions, or pattern on the inside of the lid and walls. Turn unboxing into a brand moment.
Add Inside PrintCustom Insert
A foam, cardboard, or molded-pulp insert that holds your product snugly. Prevents shifting, elevates presentation.
Design an InsertEco Upgrades
FSC-certified board, soy-based inks, and water-based coatings. Fully recyclable corrugated boxes for sustainability-focused brands.
Go GreenOur Process
From Concept to Your Customer’s Doorstep
Share Product Details
Tell us your product dimensions, weight, quantity, and preferred style. We’ll recommend the best board grade and structure.
Receive Dieline & Quote
Within 24 hours, you get a custom dieline template, 3D mockup, and a detailed quote with shipping, duties, and timeline.
Approve Sample
We produce a physical sample in 1-3 days. Test fit, check print quality, and confirm before we move to production.
Upload Artwork
Send your design files. We adjust for bleed, dieline, and print specs. Free pre-press service included.
Production
7-10 working days. We print, die-cut, fold-flat, and quality-check every box before packing.
Quality Inspection
Random sampling per batch. We check fold accuracy, print registration, color matching, and structural integrity.
Shipping & Logistics
DDP to your door worldwide. We manage freight, customs clearance, duties, and last-mile delivery.
You Receive & Assemble
Boxes arrive flat-packed and bundled. Seal RSC cartons with tape or staples in seconds, or fold mailer-style boxes and lock the lid — ready to ship to your customers.
Industries We Serve
Corrugated Boxes for Every Product, Every Brand
Apparel & Fashion
Branded RSC or mailer boxes with tissue, inserts, and thank-you notes. Tuck-top or self-locking styles.
Cosmetics & Skincare
E-flute for crisp print, soft-touch lamination, foam inserts for bottle protection.
Subscription Boxes
Monthly unboxing experience. Inside-print lid, dividers, and branded tissue options.
Food & Snacks
Food-grade liners, grease-resistant coatings, kraft or white-top surfaces.
Candles & Home
Double-wall for glass jar protection. Kraft for rustic branding, matte UV for premium.
Jewelry & Accessories
Small-product mailers with velvet insert and magnetic closure. Luxury unboxing for jewelry and accessories.
Electronics & Gadgets
Custom-cut foam inserts, anti-static options, double-wall for transit protection.
Gifts & Corporate
Foil-stamped logos, ribbon pull-tabs, premium finishes. Designed to be kept, not discarded.
What Our Clients Say
Trusted by Brands Worldwide
We switched to PackagingSmith for our subscription box packaging. The RSC cartons and self-locking mailers arrive flat and assemble in seconds — our fulfillment team loves the speed, and our subscribers love the unboxing. Print quality on kraft has been spot on every run.
We ship glass skincare bottles internationally. The E-flute corrugated boxes with foam inserts solved our breakage problem completely, and the soft-touch coating makes the box feel like a luxury gift. Exceeded expectations on every shipment.
We needed 1,200 kraft corrugated boxes for a limited-edition apparel drop. PackagingSmith kept their 7-day promise, and the print registration on kraft was spot on. Boxes arrived flat, perfectly die-cut, and assembly was effortless.
Common Questions
Corrugated Box FAQs
What is a corrugated box, and what is it made of?
A corrugated box is made from a fluted paper medium sandwiched between two flat liner boards. This three-layer structure creates a lightweight yet strong shipping container. The fluted core cushions and protects your product, while the liners provide a smooth surface for printing. It ships flat and is fully recyclable.
What is the difference between a shipping carton (RSC) and a mailer box?
An RSC (regular slotted carton) is a standard shipping box whose four flaps meet in the middle and seal with tape or staples — the workhorse of fulfillment. A mailer box is a self-locking style that folds together with no tape and is designed for a premium unboxing moment. Both are corrugated; the difference is closure and presentation.
What flute grade should I choose for my corrugated box?
For lightweight products (cosmetics, jewelry, small accessories): E-flute is ideal — thin, with a crisp printing surface. For medium-weight items (apparel, candles, subscription boxes): B-flute offers the best balance of strength and print quality. For heavy or fragile items (bottles, electronics, industrial goods): double-wall BC-flute or tri-wall provides maximum protection.
What is the minimum order quantity for custom corrugated boxes?
Our standard minimum order is 1,000 pieces per design. For certain styles and materials, we can sometimes be flexible. Reach out with your project details and we’ll find the best solution.
Can I print on both the inside and outside of the box?
Yes. Many brands print the exterior with their logo and design, and use the inside lid for a thank-you message, care instructions, or a brand pattern. Inside printing is applied during the same production run, so there is no extra lead time.
How are corrugated boxes shipped? Do they arrive assembled?
Corrugated boxes ship flat in bundles, which saves significant freight cost versus assembled boxes. RSC cartons seal in seconds with tape or staples; mailer-style boxes fold and lock with no tape. We ship DDP worldwide, handling all customs clearance, duties, and last-mile delivery.
How long does production and shipping take?
Standard production is 7-10 working days after sample approval. Shipping to the US, Europe, or Australia typically takes 15-25 days by sea freight, or 5-7 days by air freight. We’ll provide a full timeline with your quote.
Start Your Project
Let’s Design a Corrugated Box That Delivers
Request a Quote
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