- Free physical sample before the full run
- Free dieline and artwork check
- 6–8 business days from approved proof
Poly Mailers
Protect your merchandise, reduce shipping overhead, and streamline your fulfillment process with custom poly mailers built for modern retail. When you send apparel or soft goods, heavy corrugated boxes only inflate your dimensional weight charges and slow down your packing team. Lightweight yet remarkably tough, poly mailers deliver high-impact brand visibility the moment your parcel lands on your customer's doorstep. They shield every shipment from moisture, tear risks, and transit wear while keeping your logistics costs lean and predictable.
Elevate your ecommerce packaging strategy with fully customized, high-definition printing that transforms a standard shipping envelope into an interactive unboxing experience. Beyond aesthetic appeal, these mailers deliver ultimate security: tamper-evident adhesive strips lock in contents, while opaque inner layers protect customer privacy during transit. If you need extra cushioning for delicate items, seamless integration with custom bubble mailers or custom protective packaging ensures vulnerable goods arrive in pristine condition. Give your business a competitive edge with flexible, professional packaging that scales effortlessly alongside your shipping demands.
Starting from
$0.10
per box · minimum 100 boxes
Product specifications
| Specification | Details |
| Material Stock | Low-Density Polyethylene (LDPE) or High-Density Polyethylene (HDPE); Co-extruded multi-layer construction |
| Thickness / Film Gauge | 2.0 mil to 4.0 mil (50 to 100 microns); standard shipping default at 2.5 mil |
| Dimensions | Custom sizing available from $6″ \times 9″$ to $24″ \times 36″$ (Width $\times$ Height) |
| Printing Options | Flexographic printing up to 8 spot colors; full-bleed edge-to-edge printing; PMS color matching |
| Finishing & Coating | Matte, high-gloss, or soft-touch tactile finishes; anti-static release liner strips |
| Functional Add-Ons | Dual permanent self-seal strips (for easy customer returns), tear-strip openers, die-cut handle cutouts, opaque black/grey inner lining |
| Minimum Order Quantity (MOQ) | 500 units for standard custom prints; 1,000 units for bespoke sizing and full-bleed co-extruded films |
Common questions
How do poly mailers protect my clothing and textiles from moisture and dirt during transit?
Poly mailers use multi-layer co-extruded polyethylene film that forms an impermeable barrier against water, grease, and dust. Unlike standard paper envelopes or unsealed cartons, the heat-sealed side seams and permanent pressure-sensitive adhesive closures create a completely weatherproof environment, keeping garments clean and dry throughout shipping.
Are your custom poly mailers safe for wrapping wax melts or scented items directly?
Standard poly mailers are designed as secondary outer shipping envelopes rather than primary wax barriers. While the polyethylene film resists surface moisture, direct contact with essential oils or warm wax melts can cause oil migration over time. For wax-based products, pair the poly mailer with grease-resistant primary wrapping or dedicated inner packaging to ensure long-term aroma and product stability.
Can I order custom sizes to fit my specific apparel dimensions and avoid excess material?
Yes, you can customize the length, width, and lip height of your poly mailers to fit your product specs perfectly. Tailoring your dimensions prevents excess movement inside the bag, reduces total material waste, and helps you optimize dimensional weight calculations with major courier carriers.
How puncture-resistant are these mailers when handling items with firm corners or zippers?
Our co-extruded LDPE film blends tensile strength with directional stretch, allowing the material to flex around sharp edges, zippers, and hard tags without splitting. For high-density items or products with aggressive edges, choosing a 3.0 mil or 4.0 mil film thickness provides superior tear resistance and burst protection under heavy sorting pressure.
How do dual self-seal strips simplify the return process for my customers?
Dual self-seal mailers feature two parallel lines of permanent adhesive separated by a perforated tear strip. Your fulfillment team uses the first adhesive strip to seal the outbound order. If the end customer needs to return or exchange an item, they simply peel open the tear strip and seal the bag shut using the second intact adhesive strip, eliminating the need for extra tape.
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Customization options
Customer reviews
4.8
76 ratings
4.9Print quality4.8Board strength4.7Delivery speed4.8Value4.9Support
PMPriya M.4/2/20265.0
The printed colour matched our brand proof almost perfectly — no washed-out blues like the last supplier gave us. Crash-lock base holds our jars snug with zero rattling in transit.
RARebecca A.2/14/20265.0
Third reorder now. Consistent board quality every single time and the crease lines fold clean without cracking the print.
HLHannah L.3/26/20265.0
Honestly obsessed with how the full-bleed floral print turned out. The matte board feels premium and our unboxing videos have never looked this good.
JPJames P.2/6/20265.0
Needed a small first run to test the market and the low MOQ made it possible. Quality was identical when we scaled to 2,000.
DRDiego R.3/19/20265.0
Ordered a run of activity-kit boxes with a die-cut handle and window — the finish is spotless and the kids love them. Studio sorted the dieline for us in a day.
AKAisha K.1/30/20265.0
Customer service actually replies within a few hours like they promise. They caught a bleed issue in my artwork before it went to print.
AOAmara O.3/11/20265.0
Rigid gift boxes with a soft-touch lid and printed inner — exactly the luxury feel we wanted for our candle sets. Reorder was even easier than the first time.
MVMarco V.1/22/20265.0
Sturdy corrugated that survived a rough courier journey with no dents. The FSC board was a big selling point for our eco-conscious customers.
SCSofia C.2/28/20265.0
The window box with the printed stamp detailing is stunning in person. Turnaround beat the quoted lead time and the samples arrived free before we committed.
CDChloé D.1/15/20265.0
The free dieline template made designing so much less stressful. Everything lined up perfectly on the printed box.