Designer Printed Shipping Mailers

For apparel, lightweight corrugated mailers with digital or flexo printing work well since they resist tearing and moisture better than poly bags while allowing full-color branding. Optional interior printing and secure closures help protect garments in transit, and custom sizing ensures a snug fit that reduces shifting and damage during shipping.

Mailers can be produced using digital print, flexo print, or offset print depending on quantity and design complexity. Digital printing suits smaller runs with no plate charges and full-color photo-quality graphics, while flexo is cost-effective for larger volume orders with simpler color schemes.

No minimum order quantity applies to digitally printed mailers, making them accessible for startups and small-batch runs. Same-day digital quotes are available for quantities between 1 and 5,000 units using E and B flute corrugated stock, with flexo pricing available for larger volume needs.

Yes, custom corrugated and folding carton inserts can be added inside shipping mailers to cushion fragile items, organize multiple products, or add branded touchpoints. This is common for subscription boxes and direct-to-consumer shipments where both protection and presentation matter.

Most custom printed mailers are made from corrugated cardboard that is fully recyclable and often produced from recycled materials. This makes them a more sustainable alternative to plastic poly mailers or bubble wrap for e-commerce and CPG shipping applications.

Since mailers can be custom-sized to fit the exact product dimensions, right-sizing reduces void fill needs and dimensional weight charges from carriers. Working with a packaging designer to optimize size and flute strength helps balance protection with shipping cost efficiency.