Lightweight Strength. Unmistakable Storefront Branding.
Lightweight, tear-proof, and waterproof custom poly shipping envelopes for apparel and soft goods.
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
Choose materials, printing, and finishing options
Durable and cost-effective for everyday packaging needs
Natural, eco-friendly look with rustic appeal
Extra protection and strength for shipping
Thick chipboard for luxury presentation
Post-consumer recycled content with smooth surface
Bright white surface ideal for vibrant printing
Thin corrugated material with compact profile
Textured and coated papers for unique finishes
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.
