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Packaging,
different.

Custom packaging designed to scale with your brand. Designed online, printed in full color, from 10 boxes.

Design your box Compare box styles
A claw machine lifting a printed mailer box from a row of plain brown boxes
  • From 10 boxesAny mailer size, priced instantly
  • No plates or setup feesDigital print and laser cut
  • Made in North America10 to 20 days in production

A simple idea

Custom packaging shouldn’t need 10,000-unit minimums or a degree in print production. So we made it something you design and order online, from ten boxes.

We saw an industry built around huge runs and long lead times, where small businesses were priced out or left with generic brown boxes. That didn’t sit right with us.

No sales calls, no back-and-forth quoting, no volume gates. Upload your design, pick your box style, and we handle the rest, from the first click to your doorstep.

If it needs a box, we’ve probably made it.

Custom printed rigid and folding boxes arranged on bright yellow steps

Who we work with

Small brands shipping their first 10 boxes. Ecommerce companies scaling into thousands of orders a month. Promo and swag teams outfitting launches and events. Fortune 500 companies running national campaigns where every detail matters.

From idea to doorstep

Five steps, and one person
on your order the whole way.

Every box follows the same path, whatever the style. Your account manager is with you from the first upload to the day it arrives. Want to talk it through first? Get in touch.

Plain boxes riding a conveyor belt and dropping off it as printed, colorful boxes

  1. Design

    Pick a style, set your size and quantity, then build the artwork in the 3D designer or upload your own files. The price updates as you go, and you can save a design and come back to it.

    • Any mailer size, priced instantly
    • Design in 3D or upload your files
    • Save a design, finish it later

  2. Proof

    Our prepress team checks resolution, bleed and color, and your account manager emails a 2D proof of exactly what will print. Nothing goes to press until you approve it.

    • Proof within 24 business hours
    • Unlimited free revisions
    • Checked by people, not software

  3. Print

    Production starts the moment you approve. Full color goes straight onto the board on a 6-color digital press, cured instantly by UV light. No plates, labels or wraps.

    • Photo-quality, full-bleed color
    • Inside printing on every style
    • Free rush when the schedule allows

  4. Cut

    Lasers cut and crease every sheet in one pass, from a dieline generated for your order, to sub-millimeter accuracy. Nothing is tooled, so a new size costs nothing to set up.

    • No steel dies, no tooling fees
    • A different size every order
    • Artwork kept for easy reorders

  5. Deliver

    Small runs ship by parcel, big ones on a pallet by LTL freight. Corrugated and folding boxes ship flat, rigid boxes ship assembled, and tracking lands in your inbox as soon as it ships.

    • Live shipping rates in your cart
    • You choose the method at checkout
    • Tracking emailed when it ships

How it’s made

Our manufacturing
process

How we deliver custom corrugated boxes at quantities that work for you. Everything is digital, from the press to the cutting table.

Freshly printed sheets passing under the UV curing light of a digital press
Press footage

Print

Direct-to-board digital printing. No labels, no wraps, no compromise.

  • Faster Iterations

    Change your design between orders at zero cost. No plates to remake, no setup to redo. Your next version is one file upload away.

  • Lower Minimums

    Order as few as 10 boxes. Digital eliminates the fixed tooling costs that force traditional printers to require thousands of units per run.

  • Full Creative Freedom

    Photo-quality graphics, full bleeds, gradients, fine text. If you can design it, we can print it. No color count limits, no design restrictions.

Under the hood

Single-Pass & Multi-Pass
Single-pass fires ink from a full-width array in one continuous motion, for speed and consistency on large runs. Multi-pass builds color in multiple layers for deeper detail and a richer tonal range on complex artwork.
UV-Curable Inks
Cured in milliseconds by ultraviolet light into a tough polymer film that resists scratching, scuffing and fading from the moment it leaves the press. No drying time, no smearing, no waiting.
Expanded Color Gamut
Our 6-color digital press pushes well beyond standard CMYK, reproducing the vast majority of brand colors without custom ink mixing. Need exact PMS/Pantone® matching on higher quantities? Contact us about our traditional printing options.
A stack of corrugated sheets feeding into a digital laser cutter
Cutter footage

Cut

Every cut is digital. Every edge is clean.

  • Rapid Prototyping

    Test three different box sizes in the same order. Switch to a completely different dimension on the next one. Zero penalty, zero delay.

  • Any Mailer Size, Instant Price

    Enter any length, width and depth for a mailer box and get a price immediately. Shipping, folding and rigid boxes come in stock sizes, and we quote custom sizes on request.

  • No Inventory Lock-In

    Because there are no dies to amortize, you’re never locked into a box size. Evolve your packaging as your product evolves.

Under the hood

CAD & Laser Cutting
Our digital cutting system pairs an array of high-powered CO₂ lasers with a digital creasing unit: cutting, creasing and stripping in a single inline pass. Unlike traditional die cutting, the cutting and creasing patterns are fully independent, so each sheet can have a different cut pattern without retooling. The result is sub-millimeter accuracy on fine details that steel rule dies simply can’t achieve, at speeds of thousands of sheets per hour.
No Tooling, No Setup Fees
No steel rule dies to fabricate. No $1,000+ tooling charges. No week-long die lead times. Change dimensions between orders by updating a file, not by commissioning new hardware. Need die-cut production for larger runs? Contact us about our traditional cutting options.
Per-Order Dielines
Every dieline is generated digitally when you place your order. Your box dimensions go from the configurator to the cutting table with nothing fabricated in between.
A reach truck working a warehouse aisle, then a semi truck on the road
Shipping footage

Quality &
Logistics

Nothing ships until it meets spec.

  • Quality Guaranteed

    Every order goes through a multi-point inspection before it leaves our facility. Print fidelity, structural integrity, accurate counts. If it doesn’t meet spec, we reprint it at our cost. No questions asked.

  • Smart Routing

    Your order is automatically routed to the closest or most available production facility based on your shipping destination. Shorter distance, faster transit, lower cost.

  • Real Support, Real People

    Our customer service team is available by phone, email and live chat. Whether you need help with artwork, a reorder or a shipping question, you’ll always talk to a real person who knows your account.

Under the hood

Post-Production Inspection
Once your boxes come off the line, our QC team inspects color accuracy, cut precision, fold integrity and piece count. Every order is checked against your approved proof before it’s cleared to ship.
World-Class Customer Service
A dedicated account manager follows your order from file upload to delivery. Need a last-minute change? Have a question about your proof? We respond in hours, not days, and we don’t hide behind a ticket system.
FedEx®, UPS® & LTL Freight
Smaller orders ship via FedEx® or UPS®. Larger orders go LTL Freight for the best rate. Our system calculates optimal pallet configurations and compares carrier rates in real time, so you always get the fastest, most affordable option.

What drives us

Three
things
we care
about.

The values behind every box we make.

Printed mailer box with a pair of socks inside

  • Quality

    You put the work into your brand. We make sure the box lives up to it. Every order gets the same attention to detail, whether you’re testing a new design or restocking a proven one.

  • Customization

    Your brand doesn’t fit a template, and your packaging shouldn’t either. From the dimensions to the artwork, every detail is yours to decide.

  • Success

    You’re building something that matters. Your packaging should reflect that, and we’re here to make sure it does.

A printed folding carton planted with a succulent

100%recyclable through
curbside programs

Sustainability

Better packaging,
smaller footprint.

  • Cardboard, not plastic

    Our mailer and shipping boxes are corrugated cardboard: plant-based, biodegradable and accepted in curbside recycling.

  • Recycled content

    Our corrugated board contains at least 50% recycled fiber. It has likely lived several lives already.

  • Solvent-free inks

    UV-curable inks with no solvents and no VOCs. They cure instantly, so there is no heat drying.

  • Zero overruns

    No test sheets and no setup waste. We print exactly what you order, nothing more.

  • No plates, no dies

    Our digital process needs no metal plates or steel rule dies. Only the largest runs are die cut.

  • Right-sized packaging

    Any custom mailer size means less board, less void fill and less air shipped. The Box Size Optimizer finds the smallest box that works.

  • Made in North America

    Shorter supply chains mean fewer miles traveled. Your boxes don’t cross an ocean to get to you.

  • Your role

    Ordering the right size, and reordering small instead of stockpiling, cuts waste too.

Artwork

Artwork
guidelines

Great packaging starts with great artwork. Here’s everything you need to get it print-ready: file formats, bleed, color and dielines.

View guidelines

Questions

FAQ

  • Where are your boxes manufactured?

    Close to home. Our corrugated boxes, including mailer and shipping boxes, are always made in the USA. Our folding cartons and rigid boxes are made in North America. Most are made in the USA, and all within the USMCA zone.

    Making boxes on this side of the ocean means shorter lead times, fewer supply chain surprises and more consistent quality from order to order. It also keeps us close to every run, so we can stay on top of materials, print quality and finishing.

    Ordering a specialty item that isn't on our website? We'll tell you where it's made before you commit.

  • What is your minimum order quantity (MOQ)?

    Our minimum order is 10 units for mailer boxes and corrugated shipping boxes. For rigid and folding boxes, it's 500 units.

    Want to see and feel one first? Order a single printed mailer sample right from our 3D configurator. Just set the quantity to 1. It's $35 plus $6.25 shipping to the continental US, Alaska or Canada ($41.25 delivered).

    Need fewer rigid or folding boxes than the minimum? Short runs are possible case by case. Setting up a run takes about the same machine time and hands-on work for 50 boxes as for 500. On a short run that cost is shared by far fewer boxes, so the price of each one climbs steeply. If a higher price per box still works for your project, tell us what you need. We'll tell you honestly what a short run would cost.

  • How long is your production time?

    Production time is usually 10-20 calendar days, depending on quantity and box style. Rigid boxes take longer, about 30 days. Each one goes through more production steps, with an operator at every step.

    Transit adds roughly one day to a week, depending on where you are and how big the order is. All in, plan on about 2-4 weeks door to door for mailer, shipping and folding boxes, and about 5-6 weeks for rigid boxes. Enter your ZIP code on any box page or at checkout to see an estimated delivery date. Planning a launch? Confirm exact dates with us first.

    Production starts once you approve your online proof, so that's when the clock starts.

    Need it sooner? Just ask. When our schedule allows, we often expedite at no extra charge, and rush options are there for tighter deadlines. Contact us with your timeline and we'll do our best to make it work.

  • Will I get a chatbot or a real person?

    A real person, every time. Packwire uses no AI chatbots, no phone trees, and no scripted responses for customer service. Every call, email, and live chat reaches someone on our team who works with packaging daily.

    That matters most on the questions where a canned answer wastes your time: whether your artwork will hold up at print size, which board suits a heavy product, how to fit an odd-shaped item without paying for air. Your dedicated account manager can pull up your past orders and answer from those specifics rather than from a script.

    See how to reach us for phone, email, and chat hours.

All questions

Four styles.
One is yours.

Mailer, shipping, folding or rigid. See all four side by side, with what each one does best and what it costs, then design yours online in any size, from 10 units.

Compare box styles Request a quote

Rather talk to a person?

Custom sizes, large runs, a launch date to hit: tell us about your project and your account manager will take it from there.