Innovative design + reduced shipping costs + enhanced brand experience

In today’s digital marketing environment, leveraging direct mail solutions to build and cultivate customer relationships presents a costly challenge.

How can your brand stand out in the stack without the added expense?

Screenshot of a flex mailer
Flex Mailer video


Flex Mailer™ in motion

Get to know Flex Mailer — in less than 90 seconds.

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This automated flat is different.

RRD Packaging Solutions’ Flex Mailer is one-of-a-kind. Designed to convert items that would normally ship as non-automated parcels to USPS automated flats, this solution offers tremendous cost savings.

The engineered outer mailer paired with an interior tray work together to provide a supportive, yet flexible, paperboard package. The Flex Mailer’s unique presentation is ideal for brand customization to strengthen the recipient’s experience.

Size Mailer Tray
XSmall 6 1⁄2 x 5 1⁄2" 3 3⁄4 x 3 7⁄8"
Small 9 x 6 3⁄8" 6 1⁄4 x 4 3⁄4"
Classic 10 1⁄2 x 6 3⁄8" 7 13⁄16 x 4 11⁄16"
Medium 12 1⁄2 x 7 1⁄4" 9 3⁄4 x 5 5⁄8"
Large 14 1⁄2 x 8 3⁄4" 11 3⁄4 x 7"
XLarge 14 1⁄2 x 11 1⁄2" 11 3⁄4 x 9 7⁄8"
Flex Mailer

1 Product affixes to inner tray

2 Tray divides into quadrants for product placement and flexibility

3 Inner tray inserts into outer mailer

4 Designed for optimum flexibility

5 Optional hot melt seal or tear tape strip

6 Outer mailer becomes an automated flat

With Flex Mailer, brands have room to get creative with their mailings by customizing both the exterior and interior of the package. It creates engagement before the customer even opens the package or uses the product.”

— Lisa Pruett, President,
RRD Packaging Solutions

Elevate brand messaging at a significantly reduced cost.

Shifting from parcel shipping to automated flat mailing offers cost savings from USPS, and even more powerful savings when compared to FedEx, UPS, and DHL parcel shipping rates.

The Flex Mailer is smartly designed for product transit safety and made with 100% recyclable materials to deliver your brand message with a unique, thoughtful approach.

a team collaborating

Collaborate. Create. Customize.

RRD’s Flex Mailer is a patented mailing solution tailored to your unique marketing specifications. Dedicated RRD project managers and support teams provide a consultative approach for advisement on structural design and project execution.

As one of the largest printers — with best-in-class equipment — RRD is uniquely capable of producing all components of the Flex Mailer at its facilities, complemented by a wide portfolio of products and services as well as other paperboard packaging.

Unparalleled regulatory expertise

RRD’s depth of expertise related to standards and regulatory requirements makes navigating the USPS validation process an efficient one. This allows you to refocus on what’s most important: your customer.

Flexibility that matters

You need a competitive edge.
We created Flex Mailer just for you.

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