Custom Double Wall Corrugated Mailer Boxes

When a single wall box starts to bow under weight, the fix is a second layer of fluting. Double wall board puts two corrugated mediums between three liners, which roughly doubles the stacking strength without turning the parcel into a crate.

We build these for glass, ceramics, tools, bottled goods and anything over about 5 kg. The extra thickness also absorbs the knocks that happen at sorting belts, so fewer parcels arrive with dented corners and fewer customers open a claim.

You still get the clean mailer shape. The lid tucks in and locks, the corners are reinforced by the fold, and the outside can carry full colour print or stay plain kraft. If your item needs to sit still, we can add a die-cut pad or a simple corner insert in the same board.

Board grades are BC-flute or EB-flute depending on the weight you are shipping. Tell us the product weight and drop height you want to survive and we will spec the right one before you commit to a run.

Why Brands Order Custom Double Wall Corrugated Mailer Boxes

Most brands come to us because an off-the-shelf carton is either half an inch too wide or a shade too shallow. We build the dieline around the product, so it fits first time and looks intentional on the shelf.

Print space matters just as much. Every panel is usable: ingredients and compliance copy on the back, your logo and finish on the front, a short thank-you or QR code inside the lid where customers actually see it.

Board and Material Options for Double Wall Corrugated Mailer Boxes

Board choice comes down to weight and shelf position. 14pt-24pt SBS for retail cartons, E or B flute corrugated when boxes ship on their own, uncoated kraft for a recycled look, and 2-3mm rigid for gift and premium tiers.

Ask for a plain sample before you commit - it is the quickest way to feel the difference between two thicknesses.

Printing and Finishing Choices for Double Wall Corrugated Mailer Boxes

Artwork goes down in offset CMYK, digital or spot Pantone depending on quantity. Metallic and opaque white inks are available for kraft, where standard process colour tends to sink.

On top of that: matte or gloss lamination, soft-touch film, spot UV, hot foil in gold, silver, rose gold or matte black, embossing and debossing. Two finishes usually do more than four - a soft-touch base with a foil logo is the combination most brands settle on.

Wholesale Double Wall Corrugated Mailer Boxes With Low Minimums

We start at 50 units on this style. Wholesale pricing steps down as volume rises - the jump from 250 to 1,000 units is where most brands see the biggest per-box saving.

Pricing is itemised: board, printing, finishing, die and shipping listed separately, with no plate or setup fees hidden in the total.

How to Order Your Custom Printed Double Wall Corrugated Mailer Boxes

Tell us the product, the quantity and the look you are after. We return a dieline, a 3D mockup and itemised pricing, usually the same working day, and print in 8-10 business days once you sign off the proof.