How Direct Box Manufacturing Works
No sales broker handoffs or opaque third-party delays. Here is our exact, step-by-step engineering and production workflow from your first dieline to final freight delivery.
Step 1: Custom Dimensions & Instant Factory Estimate
Provide your interior length, width, and depth, or choose from our e-commerce dimension standards. Select corrugated fluting (E-Flute or B-Flute), board stock (Natural Kraft or Bleached White), and print placement. We calculate your exact volume tier with zero middleman margin.
Step 2: Free 24-Hour CAD Dieline & 3D Proofing
Our structural packaging team drafts a millimeter-accurate vector dieline (AI/PDF format) with cut lines, crease rules, and bleed margins tailored to your dimensions. Once your design team submits artwork, we return an interactive 3D digital proof for approval.
Step 3: High-Speed Inline Converting & Press Run
Your boxes enter production on our automated flexo folder gluers and rotary die-cutters. Corrugated sheets are printed with G7 calibrated water-based inks, die-cut with laser-cut steel rule dies, and scored for crisp, effortless assembly.
Step 4: Flat-Packed Palletized Delivery
Finished mailer boxes are bundled flat, edge-protected, strapped, and shrink-wrapped onto standard 40" × 48" heat-treated pallets. We coordinate LTL freight or direct full-truckload delivery right to your fulfillment dock or 3PL warehouse.
Configure Your Custom Mailer Boxes
Wholesale tiered pricing directly from the packaging floor. Receive an engineering review and guaranteed quote within 2–4 business hours.
Quote Request Received by Packaging Engineering
We are preparing your custom dieline template and wholesale volume rate breakdown. A packaging specialist will contact you at within 2–4 business hours.