Custom Padded Envelopes, Printed with Your Logo in Bulk
Turn a plain shipping mailer into branded packaging. We print your logo, colors and message onto cushioned bubble mailers — in kraft, white or poly, from tiny #000 pouches to oversized #7 sizes, with self-seal closures and eco-friendly options.
Your logo, on every mailer
Everything you need to know about custom padded envelopes
Custom padded envelopes are cushioned shipping mailers — the familiar bubble-lined or paper-padded pouches — printed on the outside with your logo, brand colors, or message. They do the same job as a plain envelope, protecting small products in transit, but they turn every parcel into a branded touchpoint. For online stores, subscription boxes, apparel labels, jewelers, and makers shipping direct to customers, that means a more professional unboxing and free advertising on the way through the mail stream.
Because they’re customized to order, the right specification depends on what you ship and how you want it to feel in a customer’s hands. This guide walks through the standard mailer sizes and dimensions, the difference between kraft, poly and paper-padded constructions, the durability and eco features that matter, how the ordering process runs from artwork to delivery, and how bulk pricing works. If you already know what you need, you can request a custom quote at any point.
A branded mailer works twice — protection and marketing
Plain brown mailers do their job and disappear. A custom padded envelope printed with your logo protects the product just the same while putting your brand in front of every warehouse worker, mail carrier, and customer who handles it. Whether you’re shipping a subscription box, a jewelry order, or a stack of paperbacks, branded mailers make your shipments look intentional and unmistakably yours.
Brand visibility
Every mailer becomes a mini billboard. Print your logo, tagline, or social handle in full color so your brand travels with the package all the way to the doorstep.
Real protection
A bubble or paper-padded lining cushions products against knocks and drops, while poly options add water resistance — so what you ship arrives the way you sent it.
Made to spec
Pick the size, material, exterior color, and print — we match your brand colors and handle bulk runs so your packaging is consistent across every order.
From your logo to your loading dock in four steps
Send your artwork
Share your logo (vector preferred), brand colors, and the mailer size and quantity you need.
We design & proof
We lay out your print, match your brand colors, and send a digital proof for review.
You approve
Confirm the proof and final quantity. Nothing goes to production until you sign off.
We print & ship
Your mailers are printed, quality-checked, and shipped to your door nationwide.
Padded envelope sizes: which one fits your product?
Bubble mailers follow a widely used numbered sizing system running from #000 up to #7. The number tells you the usable interior footprint — smaller numbers suit jewelry, cosmetics and accessories, while larger numbers handle apparel, books and bulkier goods. Here’s how the common sizes compare (exact dimensions can vary slightly by manufacturer).
Interior length by size
Length is the usable interior dimension; the outside of the mailer runs a little longer to allow for the seal flap.
Interior width by size
Choose a width that gives your product a little breathing room without leaving it loose inside the mailer.
| Size | Usable interior (W × L) | Typical fit |
|---|---|---|
| #000 Smallest | 4" × 8" | Jewelry, USB drives, small parts |
| #00 | 5" × 10" | Cosmetics, keychains, small electronics |
| #0 | 6" × 10" | Phone cases, small accessories |
| #1 | 7.25" × 12" | Small apparel, paperbacks |
| #2 Popular | 8.5" × 12" | T-shirts, softcover books |
| #3 | 8.5" × 14.5" | Larger books, folded garments |
| #4 | 9.5" × 14.5" | Tablets, framed prints |
| #5 | 10.5" × 16" | Multiple garments, larger goods |
| #6 | 12.5" × 19" | Bulky apparel, hardcovers |
| #7 Largest | 14.25" × 20" | Oversized or multiple items |
Built to protect your product and hold a crisp print
The construction of a padded envelope decides how it protects and how it prints. Kraft bubble mailers pair a tough brown or white paper exterior with an air-bubble lining that cushions against knocks — a reliable all-rounder that takes ink cleanly. Poly bubble mailers use a lightweight polyethylene shell that adds water and tear resistance, ideal for apparel and anything that shouldn’t get damp in transit. Paper-padded mailers replace the plastic bubble with a cushioned paper or honeycomb interior for a fully paper-based, recyclable option.
Every style ships with a peel-and-seal adhesive strip for fast, tape-free closing, and stays light enough to keep postage down. You choose the material and exterior color that match how and where your parcels travel — a water-resistant poly mailer for garments and a curbside-recyclable kraft mailer for eco-minded brands are built very differently, and we’ll help you weigh the trade-offs.
- Bubble-lined cushioning — air-cell interior absorbs shocks and drops
- Kraft or poly exteriors — paper durability or water-resistant plastic
- Water & tear resistance — poly shells shrug off damp and rough handling
- Peel-and-seal closure — self-adhesive strip, no tape needed
- Lightweight — helps keep parcels within lower postage brackets
- Recyclable options — paper-padded and kraft honeycomb mailers
Make the mailer unmistakably yours
Full-color logo printing
Print your logo, text, or artwork in your brand colors across one or both sides of the mailer.
Exterior color
Choose kraft brown, crisp white, black, or a custom brand color for the outside of the mailer.
Inside print
Add a printed interior — a pattern, message, or color — for a branded reveal when customers open the package.
Custom sizes
Beyond the standard #000–#7 range, we can build to a custom footprint that fits your product exactly.
Material choice
Kraft bubble, poly bubble, or fully recyclable paper-padded — matched to your product and values.
Bulk quantities
Order in volume with per-unit pricing that improves as your run size grows.
Mailer colors and finishes, and what they say
Kraft brown reads natural and eco-forward, white looks clean and premium, and bold colors make your brand pop in a mailbox. Here are the common exterior options — all printable with your logo:
Need an exact match? We print to your specified brand colors on the mailer exterior and the printed logo.
How to choose the right custom padded envelope
The best mailer comes down to what you ship and how it needs to arrive. Use this quick guide to match your product to the right size, material, and finish.
| What you’re shipping | Suggested size | Material | Why |
|---|---|---|---|
| Jewelry & small accessories | #000–#0 | Kraft bubble | Snug fit, gentle cushioning |
| Cosmetics & beauty | #00–#2 | Poly or kraft bubble | Protects glass, resists leaks |
| Apparel & soft goods | #2–#5 | Poly bubble | Water resistant, lightweight |
| Books & media | #1–#4 | Kraft bubble | Rigid support, clean print |
| Bulky or multiple items | #6–#7 | Poly or kraft bubble | Room to fit larger orders |
| Eco-minded brands | Any size | Paper-padded / recyclable kraft | Curbside recyclable, plastic-free |
Not sure which fits your product? Tell us what you ship and we’ll recommend a spec with your quote.
One mailer, many products
How custom padded envelope pricing works
Custom padded envelopes are priced per unit, and the per-mailer price drops as your quantity climbs. Your final quote depends on four things: mailer size, material, number of print colors, and total quantity. Larger runs and simpler artwork bring the unit cost down the most.
Custom padded envelope questions, answered
What’s the minimum order for custom padded envelopes?
What sizes do padded envelopes come in?
What’s the difference between kraft and poly bubble mailers?
Are your padded mailers water-resistant?
How is my logo printed on the mailer?
Can I get recyclable or eco-friendly padded mailers?
What’s the difference between a padded mailer and a plain poly mailer?
Can I choose the color of the mailer?
Do padded envelopes help lower my shipping costs?
What artwork format do you need?
What’s the typical turnaround time?
How do I get a quote?
Ready to put your brand on every mailer?
Tell us your size, quantity and material — we’ll send back exact pricing, a proof, and a production timeline. Bulk orders welcome.
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