A letterbox pack only works if it stays under a strict thickness limit. Go even slightly over, and it stops qualifying for the lower shipping rates this format is built around. We work with jewellery brands in Portland and small accessory sellers in Tampa, and thickness is the first thing we check on every design, before anything else gets finalised.
Getting the Thickness Right Without Crushing the Product
Staying thin doesn’t mean skipping protection. It means being precise about where that protection goes. We use thin, targeted padding and smart internal structure instead of a thick outer wall, so the product stays safe without pushing the pack over the limit.
Measured and Made In-House
We handle design, cutting, and printing in-house, and every letterbox design gets measured against the thickness requirement before it’s approved.
- Made at our own USA site, keeping turnaround short
- Thickness gets measured at every stage of design
- A free sample comes before any full production run
- Built specifically with small, lightweight products in mind
How a Portland Jewellery Brand Lowered Its Shipping Rate
A jewellery brand in Portland was shipping small items in a box that was just over the letterbox thickness limit, without realising it, which meant paying a higher shipping rate on every single order. We redesigned the pack with thinner, more targeted internal padding that still protected the product, and brought it safely under the limit. Shipping costs on that product line dropped noticeably the very next month.
