FAQs You have questions? No dieline needed, just scroll.

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

If you just want to see and feel one before committing to a run, you can order a single printed mailer sample for $35 plus $6.25 shipping within the continental US ($41.25 delivered) right from our 3D configurator. Just set the quantity to 1.

We can sometimes accommodate smaller quantities for folding and rigid boxes on a case-by-case basis for specialty projects. If you have a specific need, reach out to us and we'll see what we can do.

Packwire's production time is typically 10-20 calendar days, depending on quantity and box style. Transit adds roughly 1 day to a week on top of that, depending on your location and order size, so plan on about 2-4 weeks door to door. You'll see an estimated delivery date at checkout.

Production only begins once you approve your online proof, so the clock starts at approval rather than at checkout.

Need it sooner? Just ask. If our production schedule permits, we often expedite orders at no extra charge. For tighter deadlines, rush options are also available. Contact us with your timeline and we'll do our best to make it work.

Packwire manufactures its custom packaging in the United States. At Packwire, we always prioritize domestic US-based production; however, depending on availability, some products may be produced within the USMCA zone. In rare cases, specialty items (not our core product offerings available online) may be sourced outside the USMCA zone. You'll always be informed upfront before placing your order or making any payment, so there are never any surprises.

Yes. Packwire regularly produces custom packaging runs well above 2,000 units.

The 2,000-unit ceiling in our 3D configurator (3,000 for folding boxes) is a limit of the self-serve tool, not a limit on what we can manufacture. Anything above that is quoted by our team rather than priced online.

At higher volumes we can usually offer better per-unit pricing, and we may print using HD Flexo or Litho Lamination for even higher quality at scale. Contact us with your quantity, box style, and size, and we'll send you a quote.

Yes, Packwire can often accommodate rush orders, depending on our production schedule. A rush fee may apply, but sometimes we can expedite without extra charges. contact us directly to confirm rush order availability.

You can cancel your order at any time before you approve your online proof, for a full refund with no cancellation fee.

After proof approval but before production begins, cancellation is possible with a 25% fee. Once production has started, cancellations are no longer permitted.

Worth knowing: production begins immediately once you approve your proof, which is why that window is short. If you're unsure about anything, request another revision instead of approving. Revisions are unlimited and free.

Yes, quantity changes are possible right up until you accept your online proof, but not after. Send us an email and we'll process the change for you.

Yes. You can change your artwork any time before you accept your online proof. However, after you've accepted your online proof you will not be able to make any additional changes.

Packwire accepts Visa, Mastercard, American Express, Discover, Apple Pay, and Google Pay.

We also accept wire transfers and ACH for customers who prefer them, and we can issue an invoice for custom orders, reorders, and anything quoted outside the standard checkout. Invoices are payable on receipt by default; established customers can ask about credit terms such as Net 15 or Net 30, which we'll confirm in writing on the invoice itself.

Have a promo code? Enter it in the coupon field at checkout. Note that codes are case-sensitive, so paste it exactly as you received it.

To arrange a wire, ACH payment, or invoicing, contact us.

Orders shipping within the United States are not charged sales tax, and our corrugated boxes are manufactured in the United States.

Orders shipping within Canada are charged Canadian sales tax (GST, HST, or GST plus PST/QST depending on your province) on both the product and the shipping cost, calculated automatically at checkout. Our prices are listed in US dollars.

Need documentation for your records, or have a specific tax situation? Contact us and we'll help.

Packwire produces at high volume, and in print and packaging, that changes everything. Higher volume means lower costs per box, and we pass those savings directly to you. Your box price is based on five things: dimensions, box style, material, ink coverage, and quantity. You can see it update instantly in our 3D configurator as you adjust specs. The more you order, the lower your per-unit cost. For orders above 2,000 units, we can also offer alternative printing methods like HD Flexo and Litho Lamination, which can be more cost-effective at scale. Contact us anytime for a quote.

Yes. Volume pricing is built into every quote. The more you order, the lower your per-unit cost, and you can watch it update live in our 3D configurator. For larger requirements, contact us with your quantity and specs and we'll discuss wholesale pricing.

We also offer a military and first responder discount. Note that discounts can't be combined. Only one promotion or discount applies per order.

Yes. Packwire offers a 5% discount on orders under $3,000 for active military, veterans, and first responders. It applies on top of our standard wholesale and B2B pricing. For larger orders, contact us for custom pricing.

The discount covers US military, veterans, and first responders, and applies equally to Canadian Armed Forces members, veterans, and first responders. Military and first responders from other US-allied countries may qualify. Reach out and we'll take a look.

How to claim it: contact our team before you place your order, let us know your status, and we'll apply the discount. It can't be combined with other promotions or offers. Full details are on our military and first responder discount page.

There's a coupon field on the checkout page. Look for "Have a coupon code?" in the order summary, click it, paste your code, and apply it. Your discount appears in the summary before you pay.

Two things worth knowing: codes are case-sensitive, so paste it exactly as you received it rather than retyping it, and only one discount applies per order, so a promo code can't be stacked with another offer such as our military and first responder discount.

If a code isn't working or has expired, contact us and we'll sort it out.

Yes. Packwire will do its best to match a lower quote from another provider. Please note this depends on specific box type, quantity, and printing process. Reach out directly to discuss pricing details.

No, we don't charge any setup fees for products displayed on our website. Setup fees only apply to specialized custom products or complex projects that aren't listed online. Feel free to contact us directly for specifics.

Yes. Packwire can produce box styles beyond the four sold online, essentially any structure you have in mind. If you have something in mind and your order quantity is above 1,000 units, feel free to get in touch and we'll be more than happy to assist you.

You can place a reorder directly from your order history, where all your previous orders and designs are saved. Just find the order you'd like to repeat and click reorder. If you prefer, you can also reach out to your dedicated account manager and they'll take care of it for you. Need to make changes to the size, quantity, artwork, or anything else before reordering? No problem at all. Just let us know what you'd like to adjust and we'll be happy to help.

Yes. Any box you design in our 3D configurator can be saved to your account and picked up where you left off. Your saved designs live on your saved boxes page.

Every order you place also keeps its artwork on file in your order history, so you can reorder a previous design without resending any files.

You'll need a free account to save a design, the same one you use to place an order.

Your dedicated account manager will send you tracking information by email as soon as your order ships. If you have any questions about your shipment status at any time, feel free to reach out to your account manager directly or contact us and we'll get you an update right away.

All box dimensions on our site are interior measurements listed as Length × Width × Depth. This means the dimensions refer to the usable space inside the box, not the outside. The exterior will be slightly larger due to the thickness of the board. To find the right size, grab a ruler or measuring tape and measure your product at its widest, longest, and tallest points.

Tip: Add about 1/8" to 1/4" to each dimension for a comfortable fit. You want your product to sit snugly without being too tight (which can damage the box walls) or too loose (which allows shifting during shipping).

If you're shipping the product inside the box, also factor in any void fill, tissue paper, or inserts you plan to use since these take up space. For irregularly shaped items, measure the bounding box (the smallest rectangle that would fully contain the product).

Not sure which size works best? Try our Box Size Optimizer, enter your product dimensions and it'll recommend the closest standard size. You can also contact us and we'll help you find the perfect fit.

Yes, within a small manufacturing tolerance. Two things to keep in mind: the dimensions on our website are inside dimensions so you'd need to add the board thickness, and there may be a variation of up to 1/16” since we are using digital cutting tables. On shipping boxes, please allow a variation of up to 1/8” because of the glue flap.

Yes. You can download dieline templates for our standard box sizes on our guidelines page. If you need a dieline for a specific size or a specific box style, feel free to ask us and we'll provide one right away.

Yes. Packwire declines a small set of artwork, and it's worth knowing before you design. We won't print:

• Counterfeit packaging, or anything imitating another brand's trademarks, trade dress, or product identity;
• Artwork that infringes someone else's copyright, trademark, or other intellectual property;
• Content promoting hatred, violence, or discrimination;
• Sexually explicit or obscene material;
• Content promoting illegal activity, or depicting harm to minors;
• Defamatory or harassing content.

If we decline an order under this policy, you receive a full refund.

The practical thing to know: you need to own or be licensed for everything in your artwork, including logos, fonts, photography, and illustrations. We print what you give us and don't vet it for rights clearance, so if a third party raises a claim, it lands on you. If you're unsure whether you have the right to use something, sort it out before you approve your proof. Full detail is in our Terms and Conditions.

Yes. You can email your own dieline and artwork directly to us after placing an order. We accept AI, PDF, EPS, PSD, TIFF, and most other common formats. Vector files are preferred. Our prepress team will review everything for print-readiness, check bleed, resolution, and color mode, and reach out if any adjustments are needed before production.

Packwire accepts virtually any format, but vector formats (PDF, AI, EPS) are preferred. Raster files (TIFF, JPEG, PNG) should be at least 300 DPI for optimal printing quality.

Please include a 1/4" bleed on all artwork edges. CMYK colors are recommended as RGB screen colors can differ from the print result. If you have critical Pantone colors, let us know in advance.

We recommend a minimum of 9pt for standard body text. For reversed or knockout text (light text on a dark background), we recommend going slightly larger, at least 10-11pt, since ink spread can reduce legibility on smaller reversed type. Very fine serif fonts may also need to be sized up. If you're unsure, our prepress team will flag anything that might not print well before production begins.

Yes, at no extra cost. If you have artwork but aren't sure how to lay it out on a dieline, our design team will handle the placement for you at no extra cost. Just send us your artwork files and let us know your vision. We'll position everything correctly, ensure proper bleed and safe zones, and send you a proof to approve before production.

Yes. Packwire has in-house designers who provide comprehensive design support. A typical full-service package costs around $300, including up to three revisions. Minor adjustments can often be done for free or a small fee.

Yes. Every Packwire order is personally reviewed by a dedicated account manager before anything goes to press.

Here's what to expect:

1. You place your order
2. We send you a 2D proof by email
3. Your account manager checks the artwork for any issues like resolution, bleed, or color and lets you know if anything needs a tweak
4. You give us the thumbs up

Nothing goes into production until you're completely happy with how everything looks.

Yes. Packwire securely stores your artwork for a minimum of 5 years, and we do our best to keep it on file indefinitely. Once you've placed an order with us, your artwork is saved so you can easily reorder anytime without having to resend your files. You can reorder directly from your order history or simply send us a message and we'll be happy to take care of it for you.

That said, we'd always recommend keeping your own copies of your final artwork. Our retention commitment is five years from your last order, and while we do our best to keep files beyond that, we can't guarantee it indefinitely.

Yes. Proof revisions are unlimited and free. You can request changes until you're completely satisfied.

Yes. A printed corrugated sample box is $35, plus $6.25 shipping within the continental US, so $41.25 delivered.

You can order a single printed mailer sample yourself in our 3D configurator by setting the quantity to 1, with your own artwork on it. Folding and rigid box samples are provided on a case-by-case basis, so contact us for those.

Packwire makes four box styles. Here's what each one is for, with its size range and minimum order:

• Mailer Boxes are the most popular choice. Corrugated, ship-ready, and tuck closed without tape or glue. Great for e-commerce, subscription boxes, and direct-to-consumer shipping. Works as both primary packaging (the box your customer sees) and secondary packaging (the box it ships in). Any size from 2" x 2" x 2" up to 20" x 20" x 6", including fully custom dimensions. Minimum 10 units.
• Shipping Boxes are your standard corrugated box with flaps. Sturdier than mailers and ideal for heavier or larger products. Typically used as secondary or tertiary packaging to protect the product inside during transit. 7 stock sizes from 6" x 6" x 6" to 17" x 14" x 12", custom sizes by quote. Minimum 10 units.
• Folding Boxes are thin, lightweight cardstock boxes. Perfect for retail shelves, cosmetics, food, and smaller products. These are primary packaging, meant to be seen by the customer. Not designed for shipping on their own. 10 stock sizes from 2.25" x 2.25" x 3.25" to 7" x 5" x 3.5". Minimum 500 units.
• Rigid Boxes are premium, non-collapsible boxes (think phone or jewelry packaging). They arrive pre-assembled and are built to impress. Primary packaging for luxury or high-end products. Not safe to ship on their own. 9 stock sizes from 3.5" x 3.5" x 1" to 9" x 9" x 2.5". Minimum 500 units.

All dimensions are interior measurements in inches, listed as Length x Width x Depth.

Still not sure? Reach out with your product details and we'll recommend the best fit. No cost, no obligation.

Packwire uses two digital printing technologies that print directly onto the corrugated substrate. No labels, no lamination, no wraps:

Digital Single-Pass prints in a single pass at high speed using UV-curable inks that are instantly dried by ultraviolet light as the board moves through the press. This produces vibrant, durable prints that are scratch-resistant and ready to handle immediately. Ideal for larger runs with consistent color across the entire order.

Digital Multi-Pass uses the same UV-curable ink technology but makes multiple passes over the board for higher resolution and richer color depth. This is great for complex artwork, fine gradients, and photo-quality graphics on smaller to mid-size runs.

For higher quantities, we also offer traditional printing methods like HD Flexo and Litho Lamination, which can be more cost-effective at scale.

For cutting, we use CAD digital cutting tables that precisely cut and score your box shape without traditional metal dies, so no tooling costs and the flexibility to adjust sizes between orders. We also offer laser cutting, which is significantly faster than CAD cutting. For higher quantities, traditional die cutting may be used for efficiency.

Packwire offers three board finishes for mailers. Our white board is white on both sides and matte. White board is a great option to print colors. Kraft board is brown on both sides; colors will appear muted but it’s a great way to give your packaging a more natural and eco-friendly look. Our SuperGloss board is our glossy board and is the best option to give your colors an added sheen. All our boards are the same thickness.

Packwire uses different materials depending on your box style, including corrugated board, cardboard, and paper. Here's what to expect:

• Mailer boxes: E-Flute 32 ECT (200 lbs TEST) - 1/16" thickness.
  We also offer B-Flute mailers for any quantity if you need extra durability.
• Rigid Boxes: 0.50pt board + 80lbs (160m) litho paper - 1/16" thickness total
• Shipping Boxes: B-Flute 32 ECT (200 lbs TEST) - 1/8" thickness
• Folding Boxes: 16-18pt SBS Board depending on size

Do you have a special request for another board thickness? contact us and our team will be more than happy to help you!

Packwire uses 200 lbs test (32 ECT) board for both our mailers and shipping boxes. Mailers safely hold around 40 lbs per box, and our sturdier corrugated shipping boxes handle around 60 lbs.

Yes. Packwire mailer boxes are rated to ship on their own. Our mailer boxes are built with E-Flute corrugated board, which has a double-wall construction (two flat liner boards sandwiching a fluted middle layer). While E-Flute may look thin at 1/16", this structure gives it impressive strength for its weight. Our mailers are rated at 200 lbs test (32 ECT), meaning they can safely hold up to around 40 lbs of product.

They are fully compatible with all major carriers including USPS®, FedEx®, UPS®, and DHL®, and are designed to withstand the handling and sorting processes these carriers use. Customers commonly ship clothing, cosmetics, candles, subscription box products, small electronics, food items, jewelry, and promotional kits in our mailers without any additional outer packaging. The tuck-front closure keeps the box securely shut during transit, and the corrugated walls provide enough cushioning for most products. While mailer boxes can be shipped as is, we recommend adding a piece of tape to seal the closure, which also makes the package tamper-proof.

All Packwire corrugated boxes use single wall by default. If you require double-wall corrugated boxes, get in touch and we'll see what we can do for you!

Packwire's inks are graded for secondary food contact, meaning packaging food items that are already inside a protective barrier, like a sealed bag, wrapper, or jar. They are not intended for direct contact with unwrapped food.

Whether a box is suitable for a specific food application depends on the box type, materials, coatings, and intended use, so please contact us to confirm suitability before you place your order if your product is food-related.

Regulatory responsibility sits with you as the brand. Packwire manufactures to your specification and prints what you supply; we don't provide legal or regulatory advice. Specifically:

• FDA: you're responsible for ensuring your use complies with applicable FDA regulations, including 21 CFR Parts 174-186 governing food-contact materials.
• California Proposition 65: if your product requires a Prop 65 warning, you're responsible for supplying the correct warning language and making sure it appears in your artwork. We don't determine whether your product needs one.
• FTC label claims: any claims, certifications, or endorsements printed on your packaging need to comply with FTC rules, including the Fair Packaging and Labeling Act. We print what you provide without verifying it.

We're always happy to share what we know about our own materials and inks to help you make that call. Just ask.

Digital printing can't perfectly match Pantone colors, but our advanced 6-color press comes very close. For exact PMS matches, we offer HD Flexo or Litho Lamination for larger orders. Let us know your specific color needs.

Yes. Packwire offers inside printing on all box styles. It's a great way to elevate the unboxing experience. Brands commonly use it for thank-you messages, care instructions, social media handles, or full interior designs. Inside printing uses the same digital process as the exterior, so there's no loss in quality. Pricing depends on your box type and design complexity. For mailer boxes, you can design the interior directly in our 3D configurator. For other box types, contact us and we'll set it up for you.

Packwire offers a range of finishes, depending on box type and quantity, including selective varnish, foil stamping, die-cuts, window cut-outs, and foam inserts. contact us directly for available options on your order.

Yes, on rigid and folding boxes only, at quantities above 1,000 units. We can only use this process on our Rigid Boxes and Folding Boxes. Since foil stamping involves a different process we can only offer this on orders above 1,000 units. Should you want to inquire about foil stamping, just contact us and we'll be happy to help.

Not directly. Packwire does not currently have a dedicated white ink station. We can, however, print a kraft texture on white board which accurately mimics a White on Kraft look. Feel free to reach out to inquire about this process!

Yes. Packwire offers custom corrugated inserts and partitions to keep products secure and organized inside your box. Options include dividers, trays, and cradle-style inserts, all cut to fit your exact box dimensions and product shape. The minimum order for custom inserts is 500 units. contact us with your product dimensions and box size, and we'll recommend the best insert solution.

Assembly depends on your box style:

• Mailer boxes: Your mailer arrives flat. Fold along the pre-scored lines to form the base, tuck in the side flaps, and fold the lid closed using the front tuck tab. No tape or glue is needed for assembly, though we recommend a piece of tape on the tuck closure when shipping to make the package tamper-proof.
• Shipping boxes: These arrive flat but pre-glued, so assembly is quick. Simply pop open the box, fold in the bottom flaps (short flaps first, then long flaps) and seal with packing tape. Fill with your product and void fill, then fold and tape the top flaps shut.
• Folding boxes: Folding boxes ship flat and pre-glued. Fold along the pre-scored lines to form the box shape, then tuck the bottom closure into place. Our folding boxes use a tuck-end closure that snaps together easily with no glue or tape needed.
• Rigid boxes: Rigid boxes arrive fully assembled and ready to use. No folding or construction required. Simply open the lid and place your product inside.

If you have any questions about assembly or need a walkthrough for your specific box style, contact us and we'll be happy to help.

Yes. Our corrugated boards contain at least 50% recycled content, and all of our boxes are 100% recyclable through standard curbside recycling. We partner with suppliers who follow responsible forestry practices, and our digital printing process is inherently more sustainable than traditional methods. It uses no printing plates, generates less chemical waste, and allows us to print only what's needed, reducing overproduction.

Sustainability is a core value at Packwire and shapes how we source, produce, and ship your boxes.

Materials: Our corrugated boxes contain at least 50% recycled content and are 100% recyclable through standard curbside programs. We partner with suppliers who follow responsible forestry practices, and corrugated cardboard has recovery rates above 90% in North America.

Production: We use digital printing, which eliminates printing plates, reduces chemical waste, and enables true on-demand production, so we only print what you order, eliminating overproduction and excess inventory. Our precision digital die-cutting optimizes material usage and reduces board waste.

Operations: We help customers right-size their packaging with our Box Size Optimizer. Smaller boxes mean less material, less void fill, and lower shipping emissions. We also optimize shipping routes and pallet configurations to reduce fuel consumption.

Yes. You can see live shipping costs in the cart without needing to log in or create an account. Just add your boxes to the cart, enter your shipping address, and you'll see real-time shipping rates from available carriers. You can also view shipping costs during checkout if you prefer to review everything at once.

Sales tax is calculated at checkout rather than in the cart. For US deliveries there is no sales tax; Canadian deliveries are taxed by province. See Do you charge sales tax? for details.

If you have questions about shipping options or need a quote for a specific delivery scenario, feel free to contact us.

Smaller orders typically ship via parcel carriers like FedEx, FedEx Express, or UPS. Parcel shipping means your boxes are packed into one or more individual packages and sorted through the carrier's standard network, similar to how any online order would ship to your door.

Larger orders ship via LTL Freight (Less Than Truckload). With LTL, your boxes are palletized and loaded onto a shared freight truck alongside other shipments. A freight truck will pull up to your location and unload the pallet with a liftgate or at a loading dock. LTL is typically more cost-effective for larger orders because one pallet replaces dozens of individual packages, each of which would be weighed, sorted, and charged separately.

At checkout, you'll be able to choose the shipping method that works best for you. Please note that we do not currently offer USPS as a shipping option. You'll always receive tracking information upon shipment regardless of method.

Packwire ships to the United States and Canada only. We don't currently ship to other countries. If you have questions about a delivery, contact us before you order.

Yes. Packwire can split one order across multiple destinations. Just let us know the addresses and quantities for each location when you place your order, or reach out after ordering. We'll split the shipment accordingly. Additional shipping charges may apply depending on the number of destinations and shipment sizes, but we'll confirm all costs before proceeding.

Rigid boxes are an amazing display statement for your brand but it comes at a cost. The box is shipped to you pre-formed, which means that shipping can be a bit more expensive. Something to consider though is the fact that it costs less to fulfill a rigid box than a mailer as there is no assembly time.

Rigid boxes are meant to give value to your product. They are unfortunately not safe to ship on their own. We recommend that you put them in a mailer or a shipping box. Feel free to get in touch with us. We also have other options available.

Folding boxes are unfortunately not safe to ship on their own. We recommend that you put your folding box inside a mailer or a shipping box.

LTL Freight orders are shipped on a 40” x 48” pallet and delivered to your loading dock, or curbside (at the curb/driveway) if you don't have one. We can also arrange a liftgate, which is a hydraulic platform on the truck that lowers your pallet to the ground, for an additional fee. Be sure to contact us before placing your order if you have any special shipping needs. Our team will be more than happy to assist you!

No dock is fine. Deliveries without one use either curbside or liftgate service. You can contact us before or after placing your order and we'll make sure your delivery goes smoothly. Additional fees may apply depending on your delivery requirements.

For LTL Freight deliveries, there are two main options if you don't have a loading dock:

• Curbside/driveway delivery: The driver will bring the pallet to the end of the truck and lower it to ground level at the curb/driveway. From there, it's your responsibility to move it to its final location. If you have a pallet jack or forklift, you can easily move the skid yourself.
• Liftgate delivery: The truck comes equipped with a hydraulic platform (liftgate) that lowers your pallet from the truck bed to the ground. This is the easiest option if you don't have a dock or heavy equipment. A liftgate fee applies, but it's well worth it for the convenience.

Just let us know your situation and we'll recommend the best option for you.

This is more common than you'd think! Many warehouses, especially smaller or older ones, don't have a raised loading dock. The most popular option is a liftgate delivery, where the driver uses a hydraulic platform on the back of the truck to lower your pallet to ground level. From there, you can use a pallet jack or forklift to bring it inside. If your warehouse has a roll-up door or garage-style entrance, a liftgate delivery combined with a pallet jack is usually all you need. Just let us know your setup when you place your order and we'll make sure the right delivery method is selected. Additional fees may apply for liftgate service.

Yes, LTL freight can deliver to residential addresses. Just be sure to contact us before or after placing your order though, shipping rates can be different if the truck needs to go in a residential area. Additional fees may apply, feel free to reach out to know more.

You do not need to schedule a delivery date for LTL Freight by default. However, if you require a delivery appointment, please let our team know when you place your order. In most cases, we need to arrange appointments before the order ships. We can sometimes accommodate appointment requests after the order is placed but before it ships, however once the order has shipped we are unable to add an appointment. Additional fees may apply for scheduled deliveries.

Yes. If you prefer your boxes shipped loose via parcel (FedEx, UPS) instead of palletized on skids, we can accommodate that. This can be helpful if you don't have a loading dock or if you need the boxes delivered to multiple locations. Keep in mind that shipping loose on larger orders may cost more than a single pallet shipment, and handling charges and charges for master shippers will apply. Be sure to reach out before placing your order and we'll compare options for you.

Yes, Packwire can split an order across multiple addresses. Whether you need boxes shipped to a warehouse and a retail location, or split across multiple facilities, we'll coordinate it. Additional shipping fees may apply depending on the number of destinations. Get in touch with your shipping details and we'll provide an exact quote.

Yes. If you've placed separate orders and want them combined into a single shipment, reach out and we'll merge them. This can save on shipping costs, and if the combined quantity qualifies for a better price tier, we'll credit you the difference.

No. Packwire cannot ship to PO boxes; you will need a full valid address to place an order with us.

Almost always dimensional weight. Carriers bill you for the greater of your package's actual weight and its dimensional (volumetric) weight, so a large but light box is charged as if it were heavy.

As of 2026, UPS, FedEx, USPS, DHL Express and Amazon Shipping all use a divisor of 139 for US domestic parcels, fractional dimensions round up, and cubic volume above 10,368 cubic inches triggers an Additional Handling surcharge.

Our free Dimensional Weight Calculator shows the billable weight each of those five carriers would charge for any box size, flags surcharge thresholds you're close to, and tells you how much smaller the box needs to be to stop paying dimensional weight altogether. The fix is almost always right-sizing. Our Box Size Optimizer finds the smallest box your product actually fits in.

Carrier rules verified July 30, 2026. Carriers revise divisors and surcharge thresholds on their own annual cycles, so confirm current figures with the carrier before shipping.

Freight class for LTL shipments is set mainly by density: weight divided by volume, in pounds per cubic foot. Higher density means a lower class number, and a lower class means a cheaper rate.

Our free Freight Class Calculator estimates your NMFC freight class from your shipment's dimensions and weight, on the current 13-tier scale, with a legacy 18-class view if your carrier still uses it.

For reference, flat corrugated mailer boxes usually fall under NMFC 29785, general corrugated shipping containers under NMFC 29800, and corrugated partitions or dividers under NMFC 29810. Always confirm your class and NMFC code with your carrier before shipping, since some commodities carry a fixed class that overrides the density calculation.

Because class is density-driven, right-sizing your packaging is the most reliable way to lower it. Eliminating dead air inside the box raises density and can drop you a class or two on every LTL shipment.

Each carrier sets its own size and weight limits for parcels. Here is a general overview:

Packages exceeding these limits may be classified as oversized, incur surcharges, or require freight shipping. UPS and FedEx both apply large package surcharges when length + girth exceeds 130" or length exceeds 96".

Staying inside the limits is only half the cost question. What you actually get billed for is usually dimensional weight, not actual weight. Three free tools help you check before you commit to a size:

• Dimensional Weight Calculator: the billable weight UPS, FedEx, USPS, DHL Express and Amazon Shipping would each charge for your box, plus the surcharge thresholds you are near.
• Freight Class Calculator: your NMFC freight class if the order ships LTL freight rather than parcel.
• Box Size Optimizer: the smallest box your product actually fits in, which is what lowers both of the above.

For reference, Packwire's own boxes run from 2" x 2" x 2" up to 20" x 20" x 6" for mailers, and up to 17" x 14" x 12" for shipping boxes, so every size we make falls within all three carriers’ limits.

Please note: these dimensions are provided for informational purposes only and may change at any time. Always verify current requirements directly with the carrier before shipping. Carrier rules verified July 30, 2026.

Three ways to get us:

• Email: [email protected] — usually answered the same day
• Phone: 1-800-881-6093 — Monday to Friday, 9 AM to 5 PM Eastern
• Live chat: during business hours, bottom right of any page

You can also send us the details through our contact form, including artwork files if you want a second pair of eyes on them before you order.

Every customer is assigned a dedicated account manager who knows your orders, so you're not re-explaining your project every time you write in.

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.

Yes. Packwire holds a 4.8 out of 5 rating across 112 Google reviews. You can read all of them, including the critical ones, on our reviews page, or as plain text at packwire.com/reviews.txt.

They're also independently verifiable on Google rather than only on our own site: see our Google Business profile.

Packwire works toward WCAG 2.1 Level AA conformance and runs periodic accessibility audits against that standard. Our full accessibility statement covers our conformance status, known limitations, and the assistive technologies we test with.

We're open about the gaps: parts of our 3D configurator (drag-and-drop artwork placement, real-time 3D preview, and advanced color selection) can be difficult with some assistive technologies, and certain embedded third-party content may not fully conform.

If you hit an accessibility barrier anywhere on our site, tell us and we'll help you place your order directly. We aim to respond to accessibility feedback within five business days.

Packwire support is available Monday-Friday, 9 AM-5 PM Eastern Time. We typically respond immediately, though responses may take a few hours during busy periods.

Every Packwire order goes through multiple quality checkpoints. Before production, our prepress team reviews your artwork for resolution, bleed, and color accuracy. During production, our operators perform spot checks on color consistency, print alignment, and cut precision throughout the run. Before shipping, a final inspection verifies structural integrity, print quality, and correct quantities. If anything doesn't meet our standards, we reprint at no cost to you. We also keep production samples on file so we can maintain consistency across reorders.

We stand behind every order. If a printing error is on our end, we guarantee a full reprint at no charge. Just contact us within 30 days of delivery with photos of the issue and our team will take care of it. Please hold on to the affected boxes until the claim is resolved, since we may need to inspect them. For boxes damaged during shipping, reach out as soon as possible and we'll file a claim with the carrier on your behalf. We typically replace damaged boxes while the claim is being processed so you're not left waiting, though the final resolution may depend on the carrier's investigation. Our customer service team is here to make sure you're taken care of every step of the way.