- Custom poly mailers are lightweight, tear-resistant polyethylene shipping envelopes with a peel-and-seal adhesive flap that keeps clothing and soft goods dry in transit.
- Order flat mailers, expandable bottom-gusset mailers for bulky hoodies and shoeboxes, or dual-strip mailers with a second tape line for customer returns.
- Minimums depend on the product and are confirmed with your quote; standard turnaround is 10 to 14 business days, with 4 to 5 day rush production.
- Design help, custom dielines, printing plates and shipping to all 50 US states are free, and you approve a 2D proof and 3D mockup before payment.
Custom Poly Mailers
Custom poly mailers printed with your logo, brand colors or edge-to-edge pattern for shipping apparel, soft goods, footwear and e-commerce orders without corrugated box weight. Minimums depend on the product; we confirm yours with your quote. Produced in 10 to 14 business days (rush in 4 to 5), with free design help and free 50-state shipping.
What are custom poly mailers?
Custom poly mailers are flexible, waterproof e-commerce shipping bags extruded from multi-layer polyethylene film and printed with your brand logo, Pantone background color or full-bleed pattern. Built with a light-blocking dark inner lining and a smooth exterior print surface, they protect folded shirts, hoodies, activewear, yarn, bedding, cosmetics and boxed footwear from rain, conveyor belt scuffs and curious eyes in transit. Each bag comes with a pre-applied hot-melt self-sealing adhesive strip under a release liner, so warehouse packers can slide an order inside, peel the strip and press the flap shut in seconds without packing tape or void fill. Minimums depend on the product; we confirm yours with your quote. At CubitPack, custom poly mailers take 10 to 14 business days (4 to 5 days rush), with free design help, no plate fees, and free shipping to all 50 states.
Poly mailers facts
- Minimum
- Confirmed with quote
- Turnaround
- 10-14 business days
- Rush
- 4-5 business days, quoted
- Mailer styles
- Flat mailer, bottom gusset, return strip, handle
- Printing
- Spot logo or edge-to-edge CMYK and Pantone
- Finishes
- Matte, gloss, metallic foil accents
- Closure
- Tamper-evident peel-and-seal strip (single or dual return)
- Film & gauge
- Opaque co-extruded poly film
- Shipping
- Free to all 50 states
Which custom poly mailer style and closure should I choose?
| Poly mailer style | How it is built | Best for | Closure setup |
|---|---|---|---|
| Standard flat poly mailer | Two flat co-extruded panels heat-welded along both sides | T-shirts, activewear, accessories, flat soft goods | Single tamper-evident peel-and-seal strip |
| Return-ready dual-strip mailer | Flat or gusset bag with a perforated tear line and two tape strips | Apparel, swimwear and footwear with size exchanges | First strip seals outbound; second strip reseals returns |
| Bottom-gusset expansion mailer | Tucked W-fold at the base that expands 2 to 4 inches thick | Heavy hoodies, puffer jackets, shoeboxes, multi-item orders | Wide top flap with heavy-duty hot-melt adhesive |
| Full-bleed printed poly mailer | 100% edge-to-edge flood coat, repeat pattern or custom Pantone shade | D2C fashion drops, influencer kits, subscription bags | Single or dual peel-and-seal strip |
| Die-cut handle poly mailer | Extended top header with a reinforced punch-out carry handle | Omnichannel retail pickup, trade shows, shoe retailers | Bottom or mid-flap self-seal adhesive strip |
Not sure which style fits?
Request a Quote →What size custom poly mailer do I need for T-shirts, hoodies and shoeboxes?
Poly mailers are measured by flat usable Width × Height in inches, not counting the top 1.5 to 2 inch self-seal flap. Because a folded garment or box has 3D thickness, add your item's thickness to both Width and Height plus 1 inch of side clearance and 2 inches of top clearance. Whether you are comparing custom plastic shipping bags, custom apparel mailer bags, self sealing poly mailers, branded poly mailers or wholesale poly mailers, we size the template to your exact container.
| Mailer size (W × H) | Fits folded item + thickness | Common e-commerce shipments |
|---|---|---|
| 6 × 9 in | Up to 4.5 × 6.5 × 1 in | Socks, phone cases, jewelry pouches, lip gloss, sunglasses |
| 10 × 13 in | Up to 8 × 10 × 1.5 in | 1 to 2 folded T-shirts, leggings, swimwear, paperback books |
| 12 × 15.5 in | Up to 9.5 × 12 × 2.5 in | 3 to 4 shirts, crewneck sweatshirt, denim jeans, kids outfits |
| 14.5 × 19 in | Up to 11.5 × 15 × 3.5 in | Heavy fleece hoodie, knit sweaters, light jacket, small shoebox |
| 19 × 24 in | Up to 15 × 19 × 4.5 in | Winter coat, puffer jacket, adult shoebox, throw blanket, bundles |
| 24 × 24 in | Up to 19 × 19 × 5 in | Pillows, comforter sets, bulk wholesale apparel packs |
Have your inside dimensions ready? Request pricing across up to 3 quantities.
Request a Quote →How do I choose poly mailers?
- Add item thickness to width and heightA flat mailer loses width and length as it wraps around a thick item: add garment thickness to both W and H plus 1 to 2 inches.
- Pick two core sizes for 90% of ordersMost apparel brands pair a 10 × 13 inch mailer for single shirts with a 14.5 × 19 inch mailer for hoodies and multi-item carts.
- Choose single seal or dual return stripIf customers exchange clothing sizes, add a perforated tear line and second adhesive strip so they can reuse the same bag.
- Add a bottom gusset for boxesWhen shipping shoeboxes or thick folded sweaters, a 2 to 4 inch bottom gusset prevents the corners from stretching tight.
- Match film gauge to item weightLight tees ship cleanly in standard gauge film, while heavy denim, hardware or boxed shoes call for thicker puncture-resistant film.
- Leave a clear 4 × 6 inch label zoneKeep one face or a framed 4 × 6 inch rectangle free of heavy metallic or slick coatings so thermal shipping labels stick tight.
What are poly mailers made of?
Which finishes can poly mailers have?
Which features and upgrades can I add to custom poly mailers?
Poly mailers specifications
| Spec | Options |
|---|---|
| Mailer styles | Flat poly mailer, bottom-gusset expansion mailer, dual-strip return mailer, die-cut handle mailer |
| Film construction & thickness | Co-extruded polyethylene with opaque inner security layer |
| Printing | 1-to-2 color spot logo or full-bleed CMYK and Pantone printing on one or both sides; Pantone match guaranteed |
| Finishes | Matte, gloss, metallic foil accents |
| Adhesive closure | Permanent tamper-evident hot-melt peel-and-seal strip on a 1.5 to 2 in top lip; optional second strip + tear perforation |
| Size range | Standard 6 × 9 to 19 × 24 in or custom Width × Height with no die charges |
| Minimum order | Minimums depend on the product; we confirm yours with your quote |
| Proofs & samples | Free 2D proof and 3D mockup before payment; $50 sample kit or paid sample credited to order |
| Turnaround & shipping | 10-14 business days (rush 4-5 days); free shipping to all 50 US states, worldwide DDP available |
Ready to quote your poly mailers? Compare up to 3 quantities with a free 3D mockup.
Request a Quote →What do e-commerce brands ship in custom poly mailers?
Any soft, non-fragile or pre-boxed product that does not need the crush cage of a corrugated shipping carton ships faster, cleaner and at a lower postage weight inside a custom poly mailer. Share your folded garment or inner box dimensions on your quote so our team sizes the flat width, height and bottom gusset properly.
Poly mailers design ideas
Example designs with made-up brands. Your packaging is made to your design.
What are the most common custom poly mailer mistakes?
Most poly mailer issues happen when brands size bags from 2D flat measurements or forget how returns and shipping labels work in fulfillment. When specifying bulk custom poly mailers, personalized poly mailers, custom size poly mailers, standard flat poly mailer poly mailers and custom retail poly mailers, avoid these common production mistakes
- Ordering a 10 × 13 inch mailer for a 9 × 12 inch folded hoodie that is 3 inches thick, forgetting that thickness steals from both flat width and height.
- Including the 1.5 to 2 inch top adhesive flap inside your usable height calculation, which leaves the bag 2 inches too short to seal.
- Choosing a thin film gauge for sharp-cornered shoeboxes or heavy denim, allowing conveyor friction to scuff the corners in transit.
- Skipping the second peel-and-seal return strip on size-sensitive clothing, forcing customers to tape up torn bags with kitchen tape for exchanges.
- Putting critical return instructions or scannable barcodes across the top fold-over lip where the adhesive flap covers them.
Chat with a designer now
Share your logo, a sketch or an AI image. We'll rebuild every element cleanly onto your bag dieline and send a 3D mockup, free.
Made your design with AI?
Generated a concept in Google Gemini, ChatGPT, Claude or Midjourney? Send us your AI image: we rebuild every element onto your bag dieline and show you a 3D mockup before you pay, free.Custom printed poly mailers vs plain stock mailers with stickers: how do they compare?
| Plain stock poly mailers + stickers | Custom poly mailers from CubitPack | |
|---|---|---|
| First impression at the door | Plain white or gray plastic bag that looks like a generic warehouse parcel | Edge-to-edge brand color, pattern or centered logo that customers recognize right away |
| Branding labor | Requires hand-sticking a large logo sticker onto every bag before packing | Arrives fully printed and ready to peel, seal and ship in one step |
| Size & return features | Limited stock sizes with single-use glue only | Any Width × Height, optional bottom gussets and dual return tape strips |
| Color & opacity | Thin stock film can let dark garment outlines show through | Opaque dark inner security lining with guaranteed Pantone exterior color match |
| Prepress & proofing | No artwork check | Free design help, custom dieline, 2D proof and 3D mockup before payment |
Get custom poly mailers sized to your product, with a free 3D mockup before you pay.
Request a Quote →Are poly mailers safe and sustainable?
Opaque inner security lining
Co-extruded poly mailers pair a printable outer layer with an opaque black or dark gray interior layer so porch passersby cannot see the clothing or merchandise inside.Tamper-evident hot-melt seal & side welds
Once the self-sealing strip is pressed down, the permanent hot-melt adhesive cannot be peeled open without visibly stretching or tearing the polyethylene flap.Thermal shipping label & barcode adhesion check
Our prepress team checks your exterior finish and ink layout to make sure standard 4 × 6 inch ZPL thermal shipping labels bond cleanly and scan on carrier sorters.How do I order custom poly mailers?
Tell us what you need
Size, quantities or AI conceptCompare volume pricing
Dedicated account managerApprove your proof
Digital proof + 3D mockupMade and shipped
Free to all 50 statesWhat affects the cost of custom poly mailers?
The price depends on four things, and every custom quote is free.
Width × height & bottom gusset
Total square inches of polyethylene film per mailer sets the base material costFilm thickness (mil gauge)
Heavy-duty 2.5 mil and 3.0+ mil puncture-resistant films use more resin than standard 2.0 mil bagsSpot logo vs full-bleed coverage
A centered 1-to-2 color logo on a white or black bag costs less than 100% two-sided flood printingTotal quantity & return strips
Unit cost drops sharply at higher quantity tiers; dual return tape strips add a small feature costStart with a bold 1-to-2 color centered logo on a 10 × 13 inch and 14.5 × 19 inch mailer, and enter three quantities in the quote form to compare price breaks. You pay no die or plate charges, get 10% off your first order, and we beat any written US competitor quote. Buyers ordering tear resistant poly mailers or kraft and white poly mailers can compare up to three quantities in one quote.
10% off your first order.
Request a Quote →What do I need to send for a quote?
- The product and how many you need
- The inside size, or what goes in it
- A style, or ask us to suggest one
- Your logo or artwork (an AI image is fine)
- Pantone codes, if you have them
- Delivery ZIP code and the date you need it
Can I see a sample first?
Sample kit
Board and finish swatches, sample boxes, labels and bags. Credited to your first order.Digital proof + 3D mockup
See it before you payPrinted sample
Of your own designHow does shipping work?
- Free shipping to all 50 states
- Worldwide with DDP prices: duties and taxes included
- Blind and split shipping
- Damaged in transit? We reprint the damaged units free
Why brands choose CubitPack
Dedicated specialist
One account manager from quote to deliveryPantone guaranteed
Clearly off? We reprintReprint or refund
If we get it wrong, you chooseBBB accredited
A US business you can checkPoly mailers questions
What is the minimum order quantity for custom poly mailers?
Minimums depend on the product, size and print coverage, so we confirm yours with your quote. Trial runs are considered case by case, and you can compare up to three quantities in the quote form.
How do I calculate what size flat poly mailer fits a folded garment or box?
Measure your folded item's Length, Width and Thickness in inches. Mailer Width equals Item Width plus Item Thickness plus 1 inch. Mailer Height equals Item Length plus Item Thickness plus 2 inches (excluding the top adhesive flap).
Is the top self-sealing flap included in the stated height of a poly mailer?
No. Standard poly mailer dimensions (such as 10 × 13 inches or 14.5 × 19 inches) refer to the usable bag Width × Height below the fold line. The 1.5 to 2 inch peel-and-seal lip sits above that stated height.
What size poly mailer do I need for one T-shirt vs a thick hoodie?
A single folded T-shirt, polo or pair of leggings fits cleanly inside a 10 × 13 inch poly mailer. A heavy fleece hoodie, knit sweater or three to four shirts fits inside a 12 × 15.5 inch or 14.5 × 19 inch poly mailer.
How does a dual peel-and-seal return strip work on a poly mailer?
A return-ready poly mailer has two parallel hot-melt adhesive strips on the top flap with a perforated tear line between them. Customers pull the tear strip to open the bag, then peel the second adhesive strip to reseal returns.
What mil thickness should I choose for custom poly mailers?
Film thickness is measured in mils (thousandths of an inch). Standard 2.0 to 2.5 mil gauges suit soft tees and activewear, while heavier 2.5 to 3.0+ mil films resist corner pokes from shoeboxes and denim.
Can you print edge to edge (full bleed) on both sides of a poly mailer?
Yes. We can print a centered 1-to-2 color logo on a white, black or colored mailer, or print edge-to-edge CMYK and Pantone patterns across the front, back and top flap. Our Pantone color match is guaranteed.
Will thermal 4 × 6 shipping labels stick to matte or printed poly mailers?
Yes. Standard direct-thermal and thermal-transfer shipping labels adhere strongly to both matte and gloss polyethylene mailers. If your design uses metallic foil stamping, we keep a clean 4 × 6 inch zone free of foil for postage labels.
How long do custom poly mailers take to produce and ship?
Standard production takes 10 to 14 business days after you approve your 2D digital proof and 3D mockup and complete payment. Rush production in 4 to 5 business days is quoted per order. Standard shipping to all 50 US states is free.
Should I use a custom poly mailer or a corrugated mailer box?
Use a custom poly mailer for non-fragile soft goods (shirts, hoodies, socks, yarn) or pre-boxed footwear to cut shipping weight and storage space. Use a corrugated mailer box when shipping glass jars, electronics, candles or curated gift sets.
Still have a question? Ask a packaging specialist.
Request a Quote →Poly mailers terms, explained
- Co-extruded film
- Multi-layer polyethylene sheet combining a bright printable outer layer with a dark opaque inner lining
- Mil thickness
- One-thousandth of an inch (0.001 in) used to measure plastic mailer film gauge and puncture resistance
- Self-seal lip
- The 1.5 to 2 inch top flap carrying a pre-applied hot-melt adhesive strip and release liner
- Dual return strip
- Two adhesive tape strips separated by a perforated tear line so customers can reseal returns
- Bottom gusset
- A tucked fold along the bottom edge that expands 2 to 4 inches to hold thick hoodies or shoeboxes
- DIM weight
- Dimensional weight pricing used by carriers; flat poly mailers keep cubic volume and postage low
More for your apparel packaging
Learn more
Get your poly mailers price
One dedicated account manager prepares pricing across up to 3 quantities.
- Free design & AI-to-print studio + 3D mockup
- No die or plate charges · 4–5 day rush available
- Free shipping to all 50 states
- 10% off your first order
- Reprint or refund if we get it wrong
Every CubitPack service fact on this page comes from our confirmed offers (10-14 business day turnaround, 4-5 day rush, free design help, no die or plate charges and free 50-state shipping) and was checked by a packaging specialist. Garment thickness formulas and standard e-commerce mailer sizes follow USPS parcel standards. Spot something wrong? Tell us and we will fix it. Tell us if something looks wrong.
Sources
What changed
- October 22, 2026: First published.
- October 22, 2026: Updated specifications, terminology, and verified source links.