How to Make Custom Poly Mailers (and Where to Get Them)
Custom poly mailers turn a plain shipment into a branded unboxing moment. They are lightweight, waterproof, tear-resistant, and one of the most cost-effective ways to put your logo in a customer's hands. This guide walks through exactly how to make custom poly mailers — from artwork to print method — and where to get custom poly mailers printed without a huge minimum order.
What is a custom poly mailer?
A poly mailer is a flexible polyethylene shipping bag with a self-seal adhesive strip. "Custom" simply means it's printed with your branding — logo, pattern, colors, or messaging — instead of the generic grey or white you'd buy off the shelf. They're the standard choice for apparel, accessories, soft goods, cosmetics, and any non-fragile e-commerce product.
How to make custom poly mailers: step by step
1. Pick the right size
Lay your product flat and add about 2 inches on each side for sealing room. Most brands stock 2–3 sizes to cover their SKU range. Common pulls:
- Small (6x9 / 9x12): jewelry, accessories, single t-shirts. See our small bubble mailer options for padded equivalents.
- Medium (10x13): the e-commerce workhorse — fits most apparel.
- Large (14x17 / 19x24): bundles, hoodies, multi-item orders. Browse large poly mailers.
2. Choose the material
Standard custom poly mailers are 2.5–3 mil opaque LDPE. If your product needs to show through, clear poly mailers are the way to go (with a suffocation warning printed for compliance). Recycled-content and compostable films are also available if sustainability is part of your brand story.
3. Design the artwork
Keep these specs in mind:
- File format: vector (.AI, .PDF, .EPS, or .SVG). Raster files should be 300 DPI at final size.
- Color mode: CMYK for print. RGB files will shift on press.
- Bleed: add 0.25" bleed on every edge so background colors run to the trim.
- Safe zone: keep logos and text 0.5" away from the seal strip and edges.
- Coverage: full-bleed background colors are fine, but heavy ink coverage can extend production time.
4. Pick a print method
- Flexographic printing — best for runs of 1,000+ bags. Up to 6 spot colors, low per-unit cost.
- Digital printing — best for short runs and full-color photographic designs. Higher per-unit cost but no plate fees.
5. Order, proof, produce
A typical workflow looks like: upload artwork → receive a digital proof in 24–48 hours → approve → production (7–14 business days) → ship. Always check the proof carefully — that's your last chance to catch color, sizing, or spelling issues.
How much do custom poly mailers cost?
Pricing depends on size, quantity, and number of print colors. As a rough guide for a 10x13 mailer with a 1–2 color logo print:
- 250–500 units: $0.35–$0.60 per mailer
- 1,000 units: $0.20–$0.35 per mailer
- 5,000+ units: $0.10–$0.20 per mailer
Full-color or oversized designs push the upper end of those ranges.
Where to get custom poly mailers
You have a few options depending on order size and lead time:
- Specialist custom packaging suppliers (like MAILERS HQ) — low MOQs from 250 units, free design support, and fast turnaround. Best for DTC brands and Shopify stores.
- Large industrial printers — cheapest per-unit at very high volumes (10,000+), but slow and rigid on artwork changes.
- Marketplace platforms — convenient, but quality and color accuracy vary by seller.
If you want a single supplier that handles design, proofing, and printing in one place, request a custom quote and we'll send pricing and a digital mockup within one business day.
Frequently asked questions
Shipping
Can custom poly mailers ship via USPS, UPS, and FedEx?
Yes. Custom poly mailers are accepted by USPS (First Class, Priority, and Ground Advantage), UPS, FedEx, and DHL. They count as flexible packaging, so dimensional weight rules are usually more forgiving than rigid boxes. Most brands shipping under 1 lb save the most with USPS Ground Advantage or First Class Package.
Are custom poly mailers waterproof and tear-resistant for shipping?
Standard 2.5–3 mil LDPE poly mailers are fully water-resistant and rated to withstand normal handling through automated sorting equipment. For heavier or sharper items we recommend stepping up to 4 mil or using a bubble-lined mailer for extra padding.
Do printed poly mailers ship internationally?
Yes — poly mailers are accepted on every major international carrier. Just make sure your customs label and tracking sticker have a flat, non-printed area to adhere to (we leave a "label-safe" zone on every custom mailer for this reason).
Sizing
What size custom poly mailer do I need?
Measure your product flat, then add ~2 inches to the width and ~3 inches to the height for sealing room and content shifting. Most apparel brands use 10x13 as their core size, with 6x9 for accessories and 14x17 or 19x24 for bundles. See our full large poly mailer size chart.
Can I order multiple sizes in a single custom run?
Yes. Each size still needs to hit the 250-unit MOQ, but you can mix sizes in the same order and pay one setup/proofing fee. This is the easiest way to cover an entire SKU range without overcommitting on one size.
What's the smallest and largest custom poly mailer I can order?
Standard sizes range from 4x6 up to 24x36. Anything outside that range is possible as a custom-cut order but typically has a 5,000-unit MOQ and longer lead time.
Print method
Flexographic vs. digital printing — which should I choose?
Use flexographic printing if you're ordering 1,000+ units and your design uses 1–6 solid spot colors. It's the most cost-effective method at volume and produces the crispest line art. Use digital printing for short runs (250–999), photographic artwork, gradients, or full-bleed full-color designs — no plates means lower setup costs but a higher per-unit price.
How many colors can I print on a custom poly mailer?
Flexo presses handle up to 6 spot Pantone colors. Digital presses print unlimited CMYK colors, so they're the right choice for photographic or multi-color illustrations.
Can I print on both sides of the mailer?
Yes — double-sided printing is available on every print method. It typically adds 10–20% to the per-unit cost depending on coverage.
Are eco-friendly inks available?
Yes. Water-based and soy-based inks are the default on most modern presses and don't add cost. Pair them with a recycled-content or compostable film if you want a fully sustainable mailer.
Turnaround time
How long does it take to make custom poly mailers?
The full timeline runs about 2–3 weeks: 24–48 hours for a digital proof, 1–2 days for your approval, then 7–14 business days production, plus shipping (typically 3–5 business days in the US). Rush production is available and can compress this to 5–7 business days.
Is there a rush option for custom poly mailers?
Yes. Rush production is available on most orders for a 20–40% upcharge and can ship custom mailers in as little as 5 business days from artwork approval. Mention rush when you request your quote so we confirm capacity before you order.
How long does artwork proofing take?
You'll receive your first digital proof within 24–48 hours of submitting artwork. Most customers approve on the first or second revision. Production doesn't start until you've approved the proof in writing.
When should I reorder to avoid running out?
Reorder when you have about 3 weeks of stock left. That covers the standard 2–3 week production and shipping window with a small buffer. For seasonal launches (Black Friday, holiday), place reorders 6–8 weeks ahead.
Design your poly mailers online
\nUpload your logo, pick your brand colors, and preview your custom poly mailer in real time with our online design tool. When you are ready, save your mockup and request a quote — no design software required.
\n\nReady to design yours?
Pick the size that fits your product, upload your logo, and we'll handle the rest. Start with our small, large, or clear mailer options, or get a custom quote if you want something different.
