- Custom printed poly mailers turn plain plastic parcel bags into vibrant, edge-to-edge branded mailers with full-bleed Pantone floods, patterns or photographic CMYK art.
- Choose flat self-sealing mailers, wide bottom-gusset expansion mailers for thick bundles, or dual-strip return mailers with a tear perforation.
- Minimums depend on the product and are confirmed with your quote; standard turnaround is 10-14 business days with 4-5 day rush available.
- Design help, custom dielines, printing plates and shipping to all 50 US states are free, with a 2D proof and 3D mockup before payment.
Custom Printed Poly Mailers
Custom printed poly mailers with edge-to-edge Pantone flood colors, step-and-repeat patterns or full-color CMYK graphics across the front, back and sealing flap. Minimums depend on the product; we confirm yours with your quote. Made in 10-14 business days (rush in 4-5), with free design help, no die or plate charges, and free shipping to all 50 states.
What are custom printed poly mailers?
Custom printed poly mailers are weather-resistant polyethylene shipping envelopes printed with multi-color CMYK graphics, solid Pantone flood coats or edge-to-edge repeating patterns across the entire exterior surface. While basic logo mailers place a small one-color stamp in the center of a stock white bag, custom printed poly mailers let D2C fashion, footwear, beauty and subscription brands color-match the entire bag body, print wrap-around illustrations on both sides, and brand the fold-over adhesive flap. Co-extruded film pairs a smooth, corona-treated outer print skin with an opaque black or gray interior security layer that hides contents in transit. At CubitPack, minimums depend on the product and are confirmed on your quote, with 10-14 business day turnaround (4-5 days rush), free design help, no cutting die or printing plate fees, a 2D proof and 3D mockup before payment, and free shipping to all 50 US states.
Printed poly mailers facts
- Minimum
- Confirmed with your quote
- Turnaround
- 10-14 business days
- Rush
- 4-5 days, quoted
- Print coverage
- 100% full-bleed two-sided, step-and-repeat pattern, or spot graphics
- Color matching
- Full color (CMYK), Pantone match guaranteed, white ink on dark film
- Finishes
- Matte, gloss, soft-touch, metallic foil accents
- Bag styles
- Flat mailer, bottom gusset, dual return strip, punch handle
- Film & lining
- Co-extruded tear-resistant poly with opaque inner layer
- Shipping
- Free to all 50 states
Which custom printed poly mailer layout and style fits my brand?
| Printed mailer style | Print & visual coverage | Structural format | Best for |
|---|---|---|---|
| Full-bleed Pantone flood mailer | 100% solid brand color edge to edge with knockout or foil logo | Flat or bottom-gusset self-sealing bag | Signature D2C apparel, cosmetics and lifestyle brands |
| All-over repeat pattern mailer | Continuous monogram, floral, checkerboard or seasonal pattern | Two-sided print continuing across the fold-over lip | Subscription drops, kids wear, holiday capsules, creator merch |
| Photographic CMYK printed mailer | High-resolution gradients, halftone art and full-color imagery | Smooth white outer skin for true process color accuracy | Beauty clubs, activewear campaigns, limited-edition launches |
| Printed return-strip mailer | Custom instructions printed right on the perforated return lip | Dual hot-melt adhesive strips + easy-open tear perforation | Size-sensitive clothing, swimwear, intimates and footwear |
| Gusseted printed expansion mailer | Front, back and expandable bottom gusset printed in one palette | 2 to 4 in W-fold base that opens flat for thick boxes | Boxed sneakers, winter knitwear, multi-item apparel carts |
| Matte + metallic foil mailer | Satin-matte flood color paired with hot-stamped metallic foil | Heavy-gauge puncture-resistant film | Boutique fashion, leather goods, VIP influencer mailings |
Not sure which style fits?
Request a Quote →What size custom printed poly mailer do I need?
Printed poly mailers are sized by usable Width × Height in inches below the top fold line (the 1.5 to 2 inch adhesive lip is extra). When a flat envelope wraps around a thick garment or carton, it loses width and height equal to the item's height, so add your item's thickness to both dimensions plus 1 to 2 inches of loading slack. Whether you are comparing full bleed printed poly mailers, patterned poly mailers custom, colorful printed plastic shipping bags, custom pantone printed mailer bags or two sided printed e-commerce mailers, we size the template to your exact container.
| Usable size (W × H) | Max item size (L × W × Thickness) | Typical shipments & print canvas |
|---|---|---|
| 6 × 9 in | 6.5 × 4.5 × 1 in | Cosmetic cartons, jewelry boxes, socks, hair accessories, refills |
| 10 × 13 in | 10 × 8 × 1.5 in | 1-2 folded tees, sports sets, swimwear, books, 4 × 6 label on back |
| 12 × 15.5 in | 12 × 9.5 × 2.5 in | Denim jeans, crewneck fleece, 3-4 shirts, subscription bundles |
| 14.5 × 19 in | 15 × 11.5 × 3.5 in | Heavy hoodies, knit sweaters, small shoeboxes, multi-item carts |
| 19 × 24 in | 19 × 15 × 4.5 in | Puffer coats, adult shoeboxes, throw blankets, outerwear sets |
| 24 × 24 in | 19 × 19 × 5 in | Bedding sets, pillows, wholesale apparel packs, plush bundles |
Have your inside dimensions ready? Request pricing across up to 3 quantities.
Request a Quote →How do I choose printed poly mailers?
- Pick flood coat vs pattern vs CMYKSolid Pantone flood coats build instant color recognition; step-and-repeat patterns hide transit scuffs; CMYK handles gradients and photos.
- Design the fold-over top flapWhen sealed, the 2-inch top lip folds onto the back panel; use it for a contrasting color bar, tear instructions or social handle.
- Frame a 4 × 6 in postage zonePut your hero artwork on the front face and frame a clean 4 × 6 inch box on the back so thermal shipping labels never cover your art.
- Select matte or gloss finishMatte film eliminates camera glare in unboxing photos, while gloss film makes saturated neons, florals and dark inks shine.
- Add a return strip for apparelPrint simple 1-2-3 exchange icons right along a dual adhesive flap so customers can reseal returns cleanly without packing tape.
- Size for your thickest SKUAdd your folded garment's vertical thickness to both flat Width and Height, or add a bottom gusset for bulky hoodies and shoeboxes.
What are printed poly mailers made of?
Which finishes can printed poly mailers have?
Which add-ons can I get?
Printed poly mailers specifications
| Spec | Options |
|---|---|
| Print capabilities | Edge-to-edge full-bleed printing (front, back, bottom gusset and top flap), CMYK process, Pantone spot colors, white ink on dark film |
| Bag styles | Flat self-sealing mailer, expandable bottom-gusset mailer, dual-strip return mailer, die-cut handle mailer |
| Film structure & thickness | Co-extruded LDPE/LLDPE with opaque dark security interior |
| Surface finishes | Matte finish, gloss finish, protective scuff-resistant varnish, metallic foil stamping |
| Closure system | Tamper-evident permanent hot-melt peel-and-seal strip; optional second return adhesive strip with tear perforation |
| Dimensions | Standard 6 × 9 in to 24 × 24 in or any custom Width × Height with no die or plate charges |
| Minimum order | Minimums depend on the product; we confirm yours with your quote; delivered within ±5% |
| Proofs & samples | Free 2D digital proof and 3D mockup before payment; $50 sample kit or paid printed sample credited toward your 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 printed poly mailers? Compare up to 3 quantities with a free 3D mockup.
Request a Quote →Where do brands use custom printed poly mailers?
When your customer pulls an order out of their mailbox or off their front porch, a full-bleed custom printed poly mailer delivers the visual excitement of a custom printed box at a fraction of the shipping weight, postage cost and warehouse shelf space.
Printed poly mailers design ideas
Example designs with made-up brands. Your packaging is made to your design.
What are the most common custom printed poly mailer mistakes?
Full-bleed flexible mailers wrap around 3D contents and fold shut at the top lip. Avoid these five mistakes. When specifying d2c streetwear, activewear poly mailers, footwear, hats, handbags poly mailers, full color printed poly mailers and boutique poly mailers with logo, avoid these common production mistakes
- Placing a return address or website URL at the top of the back panel where the 2-inch adhesive flap folds over and covers it.
- Designing a busy dark pattern across both sides without leaving a high-contrast 4 × 6 inch zone on the back for the shipping label.
- Sizing a flat mailer without adding the garment's vertical thickness to both Width and Height, which stretches printed logos out of shape.
- Using 5 pt fine serif text reversed out of a full-bleed flood coat on flexible film, where slight ink spread can fill in tiny strokes.
- Putting metallic foil stamping right in the center of the panel where warehouse staff stick the thermal postage label.
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 vs stock printed poly mailers: which is better?
| Stock (plain) | Custom from CubitPack | |
|---|---|---|
| Print coverage | Small center stamp surrounded by wide unprinted margins | 100% edge-to-edge full-bleed color, patterns or CMYK graphics on both sides |
| Plate & setup fees | Often charges per color plate or restricts artwork to 1-2 spot inks | Zero die or printing plate charges on multi-color CMYK and Pantone runs |
| Flap & back panel design | Blank back panel and unprinted adhesive lip | Continuous pattern across the flap plus a framed 4 × 6 in postage label box |
| Scuff & weather durability | Unprotected post-printed ink that can scratch on carrier belts | Scuff-resistant matte or gloss finish over corona-treated co-extruded film |
| Color accuracy | Limited stock film colors | Guaranteed Pantone color matching with free 2D proof and 3D mockup |
Get custom printed poly mailers sized to your product, with a free 3D mockup before you pay.
Request a Quote →Are printed poly mailers safe and sustainable?
Scuff-resistant inks for automated parcel sorters
Full-bleed printed poly mailers are finished with protective matte or gloss varnish so edge-to-edge colors resist rubbing against conveyor belts and mail sacks.Opaque inner security barrier
Every printed mailer uses co-extruded film with a dark opaque interior lining so bright exterior graphics never let the contents show through under sunlight.Guaranteed Pantone match & 14-day quality pledge
We match your exact Pantone swatches and send a 2D proof and 3D mockup before payment. Report any off-spec delivery within 14 days with photos for a reprint or refund.How do I order custom printed 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 printed poly mailers?
The price depends on four things, and every custom quote is free.
Mailer dimensions & gusset
Total square inches of polyethylene film per bag sets the base resin costInk coverage & color count
100% two-sided CMYK or multi-color flood printing uses more ink than a 1-color logo on white filmFilm mil thickness & finishes
Stepping up to thicker puncture-resistant film or adding metallic foil stamping affects the unit priceOrder quantity & SKUs
Press setup spreads across the run, so unit price drops steeply from 500 to 2,500, 5,000 and 10,000+ bagsWant the look of a custom colored mailer at a lower ink cost? Print a 1-color step-and-repeat pattern or bold frame on white or black film, and compare three quantities in Step 1 of the quote form. You pay no die or plate charges, get 10% off your first order, and we beat any written US quote for the same specs.
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 checkPrinted poly mailers questions
What is the minimum order quantity for custom printed poly mailers?
Minimums depend on the product, size and print method, so we confirm yours with your quote. Small trial runs are considered case by case, and you can compare up to three quantities in the quote form.
What is the difference between custom printed poly mailers and poly mailers with logo?
Poly mailers with logo typically feature a centered 1-to-2 color brand mark on a solid bag. Custom printed poly mailers cover full-bleed edge-to-edge Pantone floods, all-over patterns, photographic CMYK artwork and printed sealing flaps.
Can you print edge to edge (full bleed) across the seams and top flap?
Yes. Because we print the polyethylene web before heat-sealing the side seams, your background color, stripes or repeating pattern can run completely edge to edge across the front, back, bottom gusset and top adhesive lip.
Do you charge extra for printing plates on multi-color poly mailers?
No. CubitPack never charges cutting die or printing plate fees. Whether your design uses a single Pantone color or full-color CMYK artwork on both sides, your quote is all-inclusive.
How do I align artwork on the top flap when it folds over onto the back?
When the 1.5 to 2 inch self-sealing lip folds down to close the bag, it overlaps the upper back panel and flips orientation. Our free 2D dieline template and 3D mockup show the exact fold line so your back graphic and flap align cleanly.
Will full-bleed ink scratch off in USPS, UPS or FedEx sorting machines?
No. We print on corona-treated polyethylene film and seal full-bleed coverage with a scuff-resistant matte or gloss varnish so colors stay intact through high-speed belt sorters and wet porch deliveries.
Do thermal 4 × 6 shipping labels stick over full-bleed printed poly mailers?
Yes, direct-thermal and thermal-transfer shipping labels bond tightly to both matte and gloss printed poly mailers. If your design includes metallic foil stamping, we keep a 4 × 6 inch postage zone free of foil.
Can I print white or metallic ink on a black or dark colored poly mailer?
Yes. We print high-opacity white ink, metallic-sheen inks or hot-stamped gold and silver foil over matte black, forest green, burgundy or custom Pantone-flooded mailers for high-contrast branding.
How long does production and shipping take for custom printed poly mailers?
Standard production takes 10-14 business days after you approve your proof and pay. Rush production in 4-5 business days is available for a quoted fee. Standard shipping to all 50 US states is free.
Can I see a 3D mockup or physical sample before my full order runs?
Every order includes a free 2D digital proof and interactive 3D mockup before payment. You can also order our $50 sample kit or a paid custom printed sample of your mailer, both credited toward your full order.
Still have a question? Ask a packaging specialist.
Request a Quote →Printed poly mailers terms, explained
- Full-bleed print
- Ink coverage that extends edge to edge across the entire front, back and flap with zero unprinted white border
- Corona treatment
- High-voltage surface preparation applied to polyethylene film so printing inks bond permanently without flaking
- Step-and-repeat
- A continuous tiled pattern of logos or icons printed across the entire mailer web
- Co-extruded poly
- Two-layer blown film with a bright white outer print surface and an opaque black inner security layer
- Fold-over lip
- The 1.5 to 2 inch top adhesive flap that folds onto the back panel to seal the parcel
- Knockout logo
- Leaving the base white film unprinted inside a solid Pantone flood coat to form a crisp white logo
More for your e-commerce packaging
Learn more
Get your printed 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 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, free 50-state shipping and guaranteed Pantone matching) and was checked by a packaging specialist. Full-bleed dieline and flap-overlap rules follow standard polyethylene converting conventions. Spot something wrong? Tell us and we will fix it. Tell us if something looks wrong.
Sources
- All CubitPack turnaround specs (10-14 business days, rush 4-5), quote-confirmed minimum, free design help, no die or plate charges, free US shipping and Pantone guarantee
- Flexographic and gravure printing registration, corona treatment and overprint varnish on LDPE film
- USPS flexible poly parcel labeling and sorting guidelines
What changed
- October 22, 2026: First published.
- October 22, 2026: Updated specifications, terminology, and verified source links.