Rigid Mailers

How to choose a rigid mailer

Size: leave room around the item

Sizes on this page are the flat size of the mailer in inches, short side first. Seams and the closure flap use part of that space, so pick a mailer at least 1/2 inch wider and 1/2 inch longer than the item.

Board thickness

Board thickness is listed in thousandths of an inch, so a higher number means thicker board. Kraft tab lock mailers here use .036 board. Kraft self-seal chipboard mailers and white tab lock mailers use .028. White self-seal mailers are mostly .018 or .020, and a few sizes use .012, .024 or .028. The kraft laminated fiberboard mailers, 7 1/4 x 10 1/2 to 14 1/2 x 18 1/2, are a separate line with a self-seal flap.

Tab lock or self-seal

A tab lock mailer closes by tucking a tab into a slot, so no tape is needed. A self-seal chipboard mailer has an adhesive strip under a liner: peel the liner and press the flap down. The self-seal chipboard mailers here also have a tear strip, so the recipient can open them without scissors.

Gusseted, side loading and top loading styles

The 7 3/4 x 10 and 9 1/2 x 12 1/2 white self-seal mailers have a 1 inch gusset that adds depth for thicker contents. The product grid also lists 12 1/2 x 15 and 14 x 17 gusseted mailers and kraft expansion mailers 3 or 4 inches deep. Side loading mailers take the item in from the side, like a standard envelope. The table marks each side loading row. The 9 x 11 1/2 white paperboard mailer is top loading.

Postage

USPS charges the large envelope price only for pieces that bend and measure no more than 12 x 15 x 3/4 inches. The USPS Domestic Mail Manual counts a rigid flat-size piece as a parcel, so most rigid mailers pay parcel prices such as USPS Ground Advantage. The 5 1/8 x 5 1/8 to 6 x 9 1/2 sizes are letter size. Filled to no more than 1/4 inch thick and 3.5 ounces, they can mail at the First-Class letter price plus the nonmachinable surcharge for rigid letters.

Buying by the case and pallet

Every row is one case of 50 to 250 mailers. Five white self-seal sizes also come in 25-packs: 6 x 8, 9 x 11 1/2, 9 3/4 x 12 1/4, 11 x 13 1/2 and 12 3/4 x 15.

Volume pricing applies at checkout: at least 3% off when the cart holds 3 or more items and at least 5% off at 6 or more, and cases of different sizes count together. Orders of one or two items with a product subtotal of $500 or more ship free when the checkout freight rate is $120 or less. Orders of three or more items get the volume discount instead of free shipping. Checkout shows the freight for your address before you pay.

For pallets, repeat orders or mixed sizes, request a delivered quote with freight priced for the whole order.

Request a bulk quote

Common questions

Related

• All mailers and envelopes
• Corrugated literature mailers
• Mailing envelopes
• Bubble mailers
• Poly mailers
• Mailer boxes
• Mailers buying guide

Table prices, stock, case counts and weights come from the live catalog.