One of the big reasons that we don't use flat rate boxes is that they are small and take lots more time to assemble. It would seriously slow down our shipping operation. Make sure you contact customer service and we'll get it sorted out for you
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Well, I had one of my last orders show up in my mailbox with the end tore wide open, Thankfully everything was still in it. Flat rate boxes come in different sizes. Personally I would think about adding some extra tape along the edges of the envelope to help reinforce it. A little extra time and some tape are cheaper than having to resend an expensive order at your own cost would be a better deal for ya. But hey, That's my 1 cents worth.