Custom Corrugated Boxes
Custom corrugated boxes are built from a fluted board layer sandwiched between flat liners, and that wavy middle is what gives them the stacking strength and crush resistance products need to survive shipping, palletizing, and storage. Packaging Vista prints corrugated boxes with your logo in any style - regular slotted carton (RSC), die-cut mailer, shipping box, full overlap, or telescoping two-piece - across E, B, C, and double-wall flute profiles, in eco-friendly kraft or bright white. With full CMYK and Pantone printing, optional gloss or matte lamination, a 100-box minimum, free design, dieline, and 3D mockup, and no die, plate, or setup fees, your boxes ship within 8 to 10 business days with free US delivery.
Key takeaways
- Built for shipping: a fluted corrugated layer between liners delivers stacking strength and crush resistance for transit and warehousing.
- Every style: regular slotted carton (RSC), die-cut mailer, shipping box, full overlap, and telescoping two-piece designs.
- Right flute, right strength: choose E, B, C, or double-wall board and match the ECT rating to your product weight.
- Go deeper: compare mailer boxes, cardboard boxes, and eco-friendly boxes, then request a free quote.
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 most economical corrugated box: four flaps on the top and bottom, with the two outer flaps meeting in the center when folded. It ships flat, assembles 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 and built in a stronger flute or double-wall board so they hold up to carrier handling and stacking on a pallet. Don't need printing? Order them unbranded as plain corrugated shipping boxes for economical bulk shipping and storage.
Full overlap (FOL)
On a full overlap box the top and bottom flaps fully overlap each other, adding a double layer of board across the faces. That extra cushioning and stacking strength suits 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 and work well for flat, large, or delicate items such as 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), which measures how much top-to-bottom stacking pressure the board can take before crushing - 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, and a smooth flute like E-flute gives crisp, high-resolution graphics. Add gloss or matte lamination for protection and shelf appeal. Every job includes a free custom dieline and 3D mockup so you approve the fit and finish before production - 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:
| Use | Recommended corrugated box |
|---|---|
| Shipping & e-commerce | Die-cut mailers or RSC shipping boxes - see mailer boxes. |
| Retail & shelf display | E-flute printed boxes for smooth graphics - see retail boxes. |
| Product packaging | Custom-sized cartons in B or E flute - see product boxes. |
| Eco-conscious brands | Recyclable kraft corrugated - see eco-friendly boxes and kraft boxes. |
| Custom shapes | Engineered die-cut designs - see die-cut boxes. |
Pricing, minimums, and turnaround
Corrugated box cost depends on size, flute and board grade (double-wall costs more than single-wall), print coverage, finishes, and quantity — for a deeper dive see our corrugated and shipping boxes guide — and the per-box cost drops as volume rises. There are no die, plate, or setup fees, the minimum is 100 boxes, and standard production runs 8 to 10 business days after proof approval, with rush available. Every order includes 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, while C-flute and double-wall constructions add stacking and shipping strength for heavier items. Tell us your product weight and use, and 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, which is the key spec for shipping and palletizing strength. We'll match the ECT rating to your product weight and stacking needs so 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 that ships flat and is taped closed, making it the most economical choice. A die-cut mailer is a one-piece box with self-locking flaps that folds up without tape, giving 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 dimensions in length x width x depth, since corrugated boxes are measured by interior space to fit the product, not the outer wall. If you're unsure, send a sample or the product specs and our team will size the box and provide 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, and a smooth flute like E-flute gives crisp, high-resolution graphics. Finishes such as gloss or matte lamination are also available with a 100-box minimum and no setup fees.
How much do custom corrugated boxes cost?
Cost depends on box size, flute and board grade, print coverage, finishes, and order quantity, and it falls as volume increases. Because every job is custom, we quote per project rather than list a flat price - but there are never die, plate, or setup fees, and the minimum is just 100 boxes. Send your dimensions 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, so it's affordable to order custom. Plan for the standard 8-10 business-day turnaround after proof approval; rush production is available if your launch date is tight, and US shipping is free.
