Lightweight Strength. Unmistakable Storefront Branding.
Lightweight, tear-proof, and waterproof custom poly shipping envelopes for apparel and soft goods.
Custom Mailer Envelopes (also known as poly mailers or shipping bags) are the go-to packaging choice for non-fragile DTC goods, soft apparel, bedding, and accessories. Built from premium co-extruded white-on-grey polyethylene film, these durable envelopes offer high resistance to tears, punctures, and weather. Equipped with a strong peel-and-seal strip, they provide a secure tamper-evident closure that streamlines fulfillment operations.
Custom Mailer Envelopes, commonly known as poly mailers, are pressure-sensitive shipping envelopes manufactured from premium co-extruded polyethylene film. The co-extrusion process welds multiple layers of plastic together, creating a material with unmatched tensile strength that resists tears, stretch, punctures, and moisture. The dark grey interior layer ensures 100% opacity, providing privacy for your shipped items.
Equipped with a high-tack, self-sealing adhesive strip, these mailers form an instant, permanent bond upon closure. Any attempt to peel open the flap will tear the plastic, making it highly tamper-evident. The flat, flexible format conforms closely to the product inside, minimizing dimensional volume and saving on shipping rates compared to rigid cardboard boxes. They are ideal for shipping clothing, blankets, handbags, and other soft goods.
Learn more in our [Complete Guide to Custom Custom Mailer Envelopes](/blog/ultimate-guide-to-mailer-envelopes).
See how businesses across different sectors use this packaging
Custom-printed mailer envelopes with full-color branding and variable data personalization drive 20-40% higher open rates than plain white alternatives.
Branded envelopes ship invoices, return labels, and loyalty cards alongside orders. Reinforces brand identity at every customer touchpoint.
Premium cotton rag or linen-finish envelopes with foil stamping create a tactile first impression for weddings, galas, and corporate events.
Tyvek-reinforced or security-tint envelopes protect sensitive contracts, tax forms, and financial statements during certified mail transit.
Flat mailer envelopes deliver lookbooks, product guides, and promotional cards inside subscription boxes for an elevated unboxing experience.
Rigid or padded mailer envelopes ship fine art prints, photographs, and certificates without bending, folding, or moisture damage.
Choose materials, printing, and finishing options
Smooth 24lb white wove stock with a classic opaque finish. Runs cleanly through laser and inkjet printers at 1,200+ sheets per hour without jamming.
Unbleached 28lb kraft paper with visible fiber texture. The raw brown surface reduces chemical processing by 40% compared to bleached alternatives.
30% post-consumer recycled fiber in a bright white 24lb sheet. Meets EPA guidelines for recycled content while maintaining print sharpness.
Spun-bonded high-density polyethylene with 7.5 psi tear strength. Resists moisture, punctures, and postal machine abrasion across 3,000+ mile transit.
25% cotton fiber content with a subtle deckle edge texture. Acid-free archival quality rated for 100+ year longevity on formal correspondence.
Premium 80lb text-weight stock with embossed crosshatch linen texture. The tactile surface increases perceived value by 35% in direct mail studies.
Chain-of-custody verified paper from responsibly managed forests. Carries the FSC Mix label accepted by 87% of environmentally conscious consumers.
30lb translucent polypropylene vellum that reveals a hint of contents inside. Creates intrigue and a 28% higher open rate for direct mail campaigns.
From concept to delivery in 4 simple steps
Share your requirements and get a detailed quote within 15 minutes during working hours. Our team reviews every project.
Receive a digital 3D mockup. Request unlimited revisions until you're 100% satisfied.
Your packaging enters production. Track progress through your dashboard in real-time.
Free shipping to your door. Standard delivery in 7-14 business days. Need it faster? Rush production delivers in 3-7 business days.
We offer sustainable alternatives for Custom Mailer Envelopes that don't compromise on quality. Choose eco-friendly materials and printing options to reduce your environmental impact.
100% Recyclable
Made from recyclable materials
FSC Certified Options
Responsibly sourced materials
Soy-Based Inks
Eco-friendly printing
Carbon Neutral
Offset shipping available
Complete technical specifications for Custom Mailer Envelopes
| finish types | Matte Poly, Semi-Gloss Poly, High-Gloss Poly |
| storage reqs | Store flat in cool, dry conditions at 60°F-80°F (15°C-27°C); keep away from direct sunlight |
| print quality | High-definition digital printing or flexographic print up to 400 DPI |
| assembly style | Side-welded envelopes with bottom fold and top self-adhesive flap |
| eco credentials | Made with up to 50% post-consumer recycled (PCR) poly, 100% recyclable |
| weight capacity | High tensile strength resists bursting during transit sorting |
| material thickness | Face stock: 2.15 mil - 3.15 mil co-extruded polyethylene film |
| production location | Printed and converted in the United States |
Experience the future of custom packaging with our AI-powered platform
Transform your ideas into print-ready packaging designs in minutes, not weeks. Our AI understands packaging constraints, bleed areas, and dieline requirements.
Get instant, expert recommendations tailored to your product. Our AI analyzes your requirements and suggests optimal materials, sizes, and finishes.
Real-time pricing in seconds
Start from just 250 units
7-14 day turnaround
Expert designers included
Worldwide delivery
100% satisfaction
Everything you need to know about Custom Mailer Envelopes. Can't find the answer you're looking for? Chat with our AI consultant.
Our AI packaging consultant can answer your specific questions and help you choose the perfect configuration.
Chat with AI ExpertOur packaging experts are available Monday-Friday, 9am-6pm.
