Custom Poly Mailers
Crafting packaging excellence, delivering your brand’s success.
Custom Poly Mailers
Custom Poly Mailers
Rigid Packaging Boxes offers custom poly mailers designed for lightweight, secure, and branded shipping across the USA and worldwide. Available in multiple materials, sizes, and printing options, these mailers protect apparel, accessories, and other non-fragile products while showcasing your brand. Every order includes free design support and free shipping, with a fast 3 to 5 business day turnaround helping businesses ship smarter without compromising on presentation or protection.
Custom Poly Mailers for Secure, Lightweight & Branded Shipping
Shipping packaging does more than protect your products — it represents your brand from the moment an order leaves your facility until it reaches your customer’s door. Custom poly mailers give businesses a lightweight, durable, and fully customizable option for everyday shipping. Whether you’re sending clothing, accessories, documents, or other non-fragile products, they cut shipping weight while keeping your packaging looking professional.
At Rigid Packaging Boxes, we know every business ships differently. That’s why our custom poly mailers come in a range of sizes, materials, colors, and printing options so you can build packaging that actually matches your products and your brand. We primarily serve businesses across the USA, while also shipping worldwide, with a turnaround time of just 3 to 5 business days, free shipping, and free design support on every order.
What Are Custom Poly Mailers?
Custom poly mailers are flexible shipping bags made from durable plastic film or eco-friendly alternatives. They’re built for products that don’t need rigid protection but still have to survive moisture, dust, and rough handling in transit.
Unlike plain shipping envelopes, they can carry your logo, artwork, brand colors, promotional messages, or QR codes — turning a basic shipping supply into packaging your customers recognize on sight. Their lightweight also helps lower shipping costs compared to boxes, which is why eCommerce and subscription brands rely on them so heavily.
Why Choose Custom Poly Mailers?
They pack product protection and shipping efficiency into one package, literally. Their flexible shape takes up far less storage space than boxes and adjusts to different product sizes without adding bulk.
- Lightweight construction that lowers shipping costs
- Water-resistant exterior that protects against moisture
- Tear- and puncture-resistant materials
- Self-sealing adhesive closure for fast packing
- Full-color printing for consistent branding
- Standard and fully custom sizes
- Recycled and biodegradable material options
- Suitable for domestic and international shipping
- Free shipping on every order
- 3 to 5 business days turnaround time
- Free design support to get your artwork print-ready
What Ships Well in Poly Mailers
Poly mailers suit soft or durable products that don’t need rigid structural support:
- T-shirts
- Hoodies
- Dresses
- Activewear
- Baby clothing
- Fashion accessories
- Scarves
- Socks
- Small textiles
- Books
- Documents
- Fabric samples
- Pet apparel
- Subscription products
- Non-fragile promotional items
For delicate items — electronics, glass, or cosmetics in fragile containers — pair these with our Rigid Mailers (for flat items) or Bubble Mailers (for extra cushioning).
Material Options
The material you pick shapes durability, appearance, sustainability, and cost. Here’s how the common options stack up:
| Material | Best For | Main Benefit |
| Polyethylene (PE) | Everyday shipping | Lightweight, water-resistant, durable |
| LDPE | Apparel & soft goods | Flexible, smooth print surface |
| HDPE | Heavier shipments | Strong tear and puncture resistance |
| Recycled Poly | Sustainability-focused brands | Cuts virgin plastic use |
| Biodegradable | Eco-conscious brands | Supports greener disposal, depending on material — check local composting/recycling rules before committing |
Custom Sizes for Every Product
Fit matters. The right size cuts down on excess movement in transit and improves presentation, plus it reduces wasted material and unnecessary package volume.
- Small — jewelry and accessories
- Medium — shirts and fashion items
- Large — jackets, blankets, multi-item orders
- Gusseted — bulkier products
- Fully custom — anything that doesn’t fit the standard grid
Printing Options
Printing is what turns a plain bag into packaging people remember.
- Digital Printing — best for detailed artwork, multiple colors, shorter runs
- Flexographic Printing — efficient for large volumes with simple designs
- Offset Printing — crisp images and precise color matching at high volume
Print can go on the front, back, or both sides: logos, taglines, QR codes, handling instructions, or a thank-you message to round out the unboxing experience.
Customization at a Glance
- Standard or fully custom sizes
- White, black, or custom colors
- Single- or double-sided printing
- Matte or glossy finish
- Custom graphics and patterns
- QR codes and promo messaging
- Self-sealing adhesive strips
- Optional resealable/return closures
Choosing the Right Mailer for Your Product
| Product Type | Recommended Mailer |
| T-shirts & apparel | Lightweight poly mailer |
| Fashion accessories | Standard custom poly mailer |
| Shoes | Gusseted poly mailer |
| Books & catalogs | Heavy-duty poly mailer or rigid packaging |
| Fragile accessories | Poly bubble mailer |
| Subscription products | Branded poly mailer |
| Eco-conscious brands | Recycled or biodegradable poly mailer |
Getting this right isn’t just cosmetic; it directly affects your shipping cost and damage rate.
Industries That Rely on Custom Poly Mailers
- Clothing & fashion retailers
- E-commerce businesses
- Subscription boxes
- Beauty & personal care
- Pet products
- Books & stationery
- Promotional merchandise
- Sportswear
- Gift shops
- Handmade & craft businesses
How to Order
- Choose your size and material
- Select printing and customization options
- Upload your logo or artwork. Our team offers free design support if you need help getting it print-ready
- Review and approve your design proof
- We move to production
- Your finished mailers arrive in 3 to 5 business days, ready to pack and ship, with free shipping included.
Double-check your artwork proof before approving colors, text, and logo placement are much easier to fix on screen than after production.
Ready to build packaging that looks as good as your product? Get a quote for your custom poly mailers today.
Get a Free Quote
Services that meet your packaging needs
Our approach delivers all the services you need to create the best packaging solutions
your products and business needs in order to achieve total packaging success.
Prototype
Identify and analyze your current packaging and spot areas of improvement for your packaging.
Packaging strategy
Collaborate and develop a tailored packaging strategy with our specialists to meet your needs and goals.
Cost optimization
Save more on your custom packaging with cost optimized strategies like material alternatives, reduction and supply chain optimization.
Supply chain optimization
Analyze and improve your existing supply chain for the most efficient procurement network.
Packaging artwork design
Work with packaging designers to create stunning artwork designs made to complement your branding.
Packaging engineering & design
Tailor packaging structures and designs to your product needs and journey with the help of dedicated engineers.
Sampling & prototyping
Test and tweak your packaging and artwork designs with samples to bring your vision to life before production.
Packaging testing
Conduct critical tests like drop and crush tests to ensure your packaging holds up to certain environments.
Material optimization
Minimize material usage to reduce unnecessary packaging waste and material costs with our structural engineers.
Strategic sourcing
Get your packaging strategically sourced to reduce your overall shipping costs and lower your carbon footprint.
Managed manufacturing
Manufacture your packaging at managed facilities for top quality assurance and reliable results no matter where you are.
Multi-packaging ordering
Build an entire product line in one place using a range of certified facilities worldwide for every piece of your packaging.
Quality control management
Have confidence in your packaging materials through managed stringent quality control and monitoring.
Route optimization
Ensure on-time deliveries with reduced carbon emissions through working with our dedicated logistics team.
Cargo optimization
Keep costs low with optimized solutions designed to save space on cargos and ensure on time deliveries.
Just-in-time delivery
Work with a dedicated product specialist to ensure all componets of your packaging are ready for your launch date.
End-to-end delivery
Let us handle every step of your shipping your packaging order to ensure safe and on-time deliveries.
Customer satisfaction
Build a loyal customer base and make a good first impression with solutions optimized to your target market.
Project evaluation
Evaluate your packaging process with a packaging expert to develop strategies for smoother operations.
Project optimization
Optimize your packaging for smoother supply chain operations and an improved return on investment.
Related Products
Discover Packaging Solutions through Our *Informative FAQ.
Find quick answers and insights in our helpful FAQ—your guide to smarter packaging solutions.
Clothing, fabric goods, accessories, documents, books, and other durable, non-fragile items.
Most polyethylene mailers resist moisture well, protecting contents from rain and humidity in transit.
Yes — logos, graphics, promotional messages, and QR codes can all be printed on.
Standard mailers suit soft, durable goods; bubble mailers add an interior cushioning layer for delicate items.
Yes — recycled, biodegradable, and reusable options are all available depending on your sustainability goals.
Yes, beyond standard dimensions, mailers can be manufactured to fit your specific product.
Most orders are completed and shipped within 3 to 5 business days.
Yes — while our main focus is the USA, we ship worldwide.
Yes, we offer free design support to help get your artwork print-ready.
Yes, free shipping is included on every order.
Reviews
There are no reviews yet