Custom Corrugated Boxes

Custom corrugated boxes are built from a fluted board layer between flat liners. That wavy middle gives them the stacking strength and crush resistance products need. It handles shipping, palletizing, and storage.

Packaging Vista prints corrugated boxes with your logo in any style. Choose regular slotted carton (RSC), die-cut mailer, shipping box, full overlap, or telescoping two-piece. Flute profiles include E, B, C, and double-wall. Stock choices are eco-friendly kraft or bright white.

Print in full CMYK and Pantone. Add gloss or matte lamination. Order from just 100 boxes with no die, plate, or setup fees. Get free design, dieline, and 3D mockup. Your boxes ship in 8 to 10 business days with free US delivery.

Corrugated box styles

The structure decides how the box folds, ships, and protects. These are the corrugated styles we make most often:

Regular slotted carton (RSC)

The RSC is the most common and cheapest corrugated box. It has four flaps on the top and bottom. The two outer flaps meet in the center when folded. It ships flat, folds up fast, and suits most product and shipping needs.

Die-cut mailer boxes

A one-piece die-cut mailer folds up with a self-locking front tab and wing flaps. No tape needed. The clean interior and printable exterior make it the go-to for e-commerce, subscription, and retail unboxing. See our dedicated mailer boxes for more.

Shipping boxes

Standard corrugated shipping boxes are sized to your product. They use a stronger flute or double-wall board. They hold up to carrier handling and stacking on a pallet. Don't need printing? Order them unbranded as plain corrugated shipping boxes for cheap bulk shipping and storage.

Full overlap (FOL)

On a full overlap box the top and bottom flaps overlap fully. That adds a double layer of board across the faces. The extra cushioning and stacking strength suit heavier products and rough transit.

Telescoping (two-piece) boxes

A separate lid telescopes over a matching base, like a tray and cover. Telescoping boxes add rigidity. They work well for flat, large, or delicate items. Think framed art, apparel, and printed goods.

Flute profiles and board strength

The flute is the wave-shaped middle layer, and its size sets the board's thickness, cushioning, and print quality:

• E-flute (about 1/16-inch) is thin with a smooth surface for crisp, high-resolution retail printing.
• B-flute (about 1/8-inch) is a versatile all-rounder with good crush resistance and a flat print face.
• C-flute (about 3/16-inch) adds more cushioning and stacking strength for shipping cartons.
• EB double-wall combines a fine E and a larger B flute for heavy-duty strength with a printable surface.

Board strength is rated by ECT (Edge Crush Test). It measures how much top-to-bottom stacking pressure the board can take before crushing. It is reported in pounds per linear inch, for example 32 ECT or 44 ECT. We match the flute and ECT rating to your product weight and stacking needs.

Custom corrugated boxes with your logo

We print corrugated to your exact artwork in full CMYK with Pantone-matched color. A smooth flute like E-flute gives crisp, high-resolution graphics. Add gloss or matte lamination for safety and shelf appeal.

Every job comes with a free custom dieline and 3D mockup. You approve the fit and finish before we print. No die, plate, or setup fees, from the first 100 boxes.

Corrugated boxes by use

Corrugated suits any product that needs protection in transit or on the shelf:

Pricing, minimums, and turnaround

Corrugated box cost depends on size, flute and board grade, print coverage, finishes, and quantity. Double-wall costs more than single-wall. For a deeper dive see our corrugated and shipping boxes guide. The per-box cost drops as volume rises.

There are no die, plate, or setup fees. The minimum is 100 boxes. Standard runs take 8 to 10 business days after proof approval, with rush on hand. Every order comes with a free dieline, 3D mockup, and free US shipping. Shipping high volume? See why brands choose a US corrugated box manufacturer. Request a free quote with your size and quantity for exact pricing.

Frequently Asked Questions

Which flute grade should I choose for my corrugated boxes?

It depends on the job. E-flute (about 1/16-inch) and B-flute (about 1/8-inch) are best for retail and product boxes that need a smooth print surface. C-flute and double-wall builds add stacking and shipping strength for heavier items. Tell us your product weight and use. We'll recommend the right flute.

What is ECT and how do I know my box is strong enough?

ECT (Edge Crush Test) measures how much top-to-bottom stacking pressure the board can take. That is the key spec for shipping and pallet strength. We'll match the ECT rating to your product weight and stacking needs. Your boxes hold up through transit and warehouse storage.

What is the difference between an RSC and a die-cut mailer box?

An RSC (regular slotted carton) is the standard four-flap shipping box. It ships flat and is taped closed. That makes it the cheapest choice. A die-cut mailer is a one-piece box with self-locking flaps. It folds up without tape and gives a cleaner unboxing for e-commerce and retail. We make both styles to your size.

How should I provide dimensions so my corrugated box fits correctly?

Give us the inside sizes in length x width x depth. Corrugated boxes are measured by inside space to fit the product, not the outer wall. If you're unsure, send a sample or the product specs. Our team will size the box and give you a custom dieline.

Can corrugated boxes be printed in full color with our branding?

Yes. We print corrugated in full CMYK and can match Pantone colors. A smooth flute like E-flute gives crisp, high-resolution graphics. Finishes like gloss or matte lamination are also on hand. The 100-box minimum and no setup fees still apply.

How much do custom corrugated boxes cost?

Cost depends on box size, flute and board grade, print coverage, finishes, and order quantity. It drops as volume rises. Every job is custom, so we quote per project rather than list a flat price. There are never die, plate, or setup fees. The minimum is just 100 boxes. Send your sizes and quantity for an exact, no-obligation quote.

What is the lead time and minimum order on corrugated boxes?

The minimum is 100 boxes with no die, plate, or setup fees. It stays affordable to order custom. Plan for the standard 8-10 business-day turnaround after proof approval. Rush production is on hand if your launch date is tight. US shipping is free.