Standard: 18 to 20 Business Days
Express: 12 to 14 Business Days
Expedite: 8 to 10 Business Days
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Price Match Guarantee
3D Design Services
Flexible Lead Times
High-Volume Printing
24/7 Support
Low Minimum
Free Design Support
Poly Bubble Mailers
We make custom poly bubble mailers for brands shipping small products that want every package to arrive undamaged and visibly branded. Each mailer pairs a poly outer film with a bubble lining, cushioning the product while keeping shipping weight low. You choose the size, shape, film color, and printed design. We size each mailer to fit your product and print it to match your brand. You may also know them as bubble envelopes, padded poly mailers, or cushioned mailers.
final cost depends on your specifications
Price as low as
instock
Warranty
Estimated arrival:
Standard: 18 to 20 Business Days
Express: 12 to 14 Business Days
Expedite: 8 to 10 Business Days
Poly Bubble Mailers
We make custom poly bubble mailers for brands shipping small products that want every package to arrive undamaged and visibly branded. Each mailer pairs a poly outer film with a bubble lining, cushioning the product while keeping shipping weight low. You choose the size, shape, film color, and printed design. We size each mailer to fit your product and print it to match your brand. You may also know them as bubble envelopes, padded poly mailers, or cushioned mailers.
final cost depends on your specifications
Price as low as
instock
Warranty
Personalized Poly Mailers for E-Commerce Shipping
On the way to your customer, an online order is sorted, loaded onto trucks, and left on a doorstep. A plain envelope offers no cushioning. A box adds weight and volume. A poly mailer adds cushioning without the weight or bulk of a box.
The outer film resists moisture and tearing. The bubble lining absorbs impacts during handling.
That combination suits products that need cushioning, which a standard poly mailer doesn’t provide:
- Cosmetics
- Jewelry
- Accessories
- Phone cases
- Small electronics
- Books
We Size the Mailer Around Your Products
Your product’s dimensions set the mailer size. A mailer that’s too large lets the product shift. One that’s too tight strains the seal.
Your product’s thickness matters as much as its length and width. The bubble lining takes up internal space, so we size by the mailer’s usable inner dimensions, not its flat outer measurements.
Weight and fragility affect the amount of clearance the product needs. A single lipstick and a boxed set of earbuds require different amounts of internal space, even in the same mailer style.
What goes into each order matters too. If you ship a single item, the mailer can fit snugly. If you ship bundles, we size for the largest combination you send.
What You Can Customize
| Option | What It Decides |
| Size | The mailer’s inner dimensions and how closely it fits your product |
| Shape and proportions | Whether the mailer suits flat, long, or bulky items |
| Film color | The base color before printing |
| Printed design | Your logo, brand colors, patterns, and messaging |
| Print placement | Where your artwork appears on the mailer |
Turn the Mailer Into Branded Packaging
A poly bubble mailer is the first part of your order that your customer touches. Its printed surface carries your brand from your warehouse to their doorstep.
We can print your:
- Logo
- Brand colors
- Patterns
- Social handles
- Messages
Shipping labels cover part of the front, so we plan your artwork around the label area to keep your logo and key messages visible.
Choose film color and artwork together:
- A bold film color can stand on its own with a simple logo.
- A detailed pattern needs a plain background to stay legible.
What Affects Poly Bubble Mailer Cost?
Pricing of these custom poly bubble mailers depends on:
- Size. Larger mailers use more film and lining.
- Quantity. Higher quantities usually lower the unit cost.
- Artwork. Detailed artwork requires more print setup.
- Print coverage. Printing more of the mailer’s surface uses more ink.
Because these factors vary by order, The Premier Packaging quotes each custom order based on its specifications instead of a fixed price list.
Poly Bubble Mailers vs. Other Shipping Packaging
If your product needs cushioning but not the bulk of a box, a poly bubble mailer is the right fit. Still, there comes a time when you’ll have to make an informed decision about which poly bubble mailers to choose. Please refer to the following table to learn how to make an informed decision when buying custom poly mailers compared with other shipping mailers.
| Feature | Poly Bubble Mailer | Standard Poly Mailer | Mailer Box |
| Cushioning | Built-in bubble lining | None | Requires inserts or void fill |
| Weight | Light | Lightest | Heavier |
| Best for | Small items that need cushioning | Soft goods like apparel | Rigid or premium products |
| Branding surface | Printed outer film | outer film (Printed) | Printed box panels |
Shop Poly Mailers — No Minimums & Free Design Help
Join the pool of over 1,000+ happy customers who trust The Premier Packaging for custom boxes to solve packaging problems.
You can get in touch with our packaging experts by phone at (727) 629-1270 or by email at inquiry@thepremierpackaging.com.
| Dimensions | All Custom Sizes & Shapes |
| Printing | CMYK, PMS, No Printing |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Quantities | 100 – 500,000 |
| Coating | Gloss, Matte, Spot UV |
| Default Process | Die Cutting, Gluing, Scoring, Perforation |
| Options | Custom Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink, PVC Sheet |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turn Around Time | 4-6 Business Days, Rush |
Aqueous Coating
A clear, water-based coating that dries quickly and protects printed surfaces to improve surface appearance.
UV Coating
A liquid coating that is cured instantly with ultraviolet light to create scuff-resistant matte surface.
Spot UV Coating
A UV coating applied only to selected areas (like logos or text). Used for contrast and visual impact.
Soft Touch Coating
A coating that creates a smooth, velvet like feel to add a premium tactile experience. Can slightly reduce scratch resistance if not laminated.
Varnish
A thin, clear liquid coating applied during printing using the printing press (CMYK process).
Lamination
A plastic film bonded to the printed surface for strong protection against moisture, tearing, and wear.
Anti-Scratch Lamination
A special BOPP film lamination designed to resist scratches and scuffs to prevent fingerprints and surface marks.
Soft Touch / Silk Lamination
A laminated film with a silky, peach-skin texture that feels soft and luxurious in hand.
Offset Printing
It utilizes metal plates and a rubber blanket to transfer ink to paper. It’s ideal for large runs to get sharp detail and color consistency.
Digital Printing
Prints directly from digital files without plates. Ideal for short runs, fast turnaround, and cost-effective small quantities.
UV Printing
Ink is cured instantly using UV light, creating durable prints with gloss or raised effects on coated and specialty surfaces.
Water-based Ink
Made with water and pigments instead of solvents. More eco-friendly than oil inks, commonly used in paper packaging.
Soy / Vegetable Ink
Uses soy or vegetable oils with pigments. Offers vibrant color and lower VOCs, but not fully impact-free.
Oil Based Ink
Petroleum-based ink that delivers rich, durable color. Traditional and effective, but less sustainable and harder to recycle.
Pantone (PMS Colors)
Standardized color system using exact ink formulas to ensure consistent and accurate brand colors across print jobs.
Pantone Metallic
Pantone inks with metallic particles for shiny finishes. Used for premium looks but can reduce recyclability.
SBS C1S
Premium bleached white board, coated on one side for sharp prints. Recyclable; biodegradable if coating is eco-friendly.
SBS C2S
Premium bleached white board, coated on both sides for quality prints inside and out. Coating affects its biodegradability.
CCNB
Duplex board with white front and gray back, mostly recycled. Clay coating may limit biodegradability.
Fully Recycled CCNB
Board from 100% recycled fiber, coated on one side. Recyclable; coating may affect biodegradability.
Natural Brown Kraft
Brown kraft board from virgin and recycled pulp. Strong, eco-friendly, mostly uncoated. Recyclable & biodegradable.
White Kraft
Bleached kraft board from virgin and recycled pulp. Coated or uncoated; recyclable, biodegradable if coating is eco-safe.
Black Kraft
Black-dyed kraft from virgin and recycled pulp. Recyclability depends on dye/coating; less biodegradable than natural kraft.
Uncoated Unbleached Kraft
Natural kraft board, no bleaching or coating. Fully recyclable, fully biodegradable, very sustainable.
Hot Foil Stamping
A printing process where metallic or pigmented foil is transferred onto a surface using heat and pressure to create a shiny, decorative effect.
Cold Foil Printing
Foil is transferred onto a surface without heat using UV-curable adhesives and a printing press. Suitable for high-speed commercial printing and flexible materials.
Blind Embossing
A design is raised on a surface without any foil or color, using a die pressed from the front side of the material. This creates a subtle, tactile effect.
Blind Debossing
A design is pressed inward into the material from the front side, creating an indented effect without foil or ink.
Registered Embossing
Embossing that aligns precisely with another printed element (like a logo or foil). Ensures the raised design matches the printed artwork.
Combination Embossing
Embossing combined with foil stamping in a single pass. Produces a raised design that also has a metallic or colored foil finish.
Window Patching
A die-cut opening on packaging is covered with a thin plastic film. Give customers a chance to see the inside of packaging for visibility purposes.
GSM
Measurement for the density of the paper stock.
PT
Measurement for the thickness of the paper stock.
Flute
Fiberboard arches sandwiched between two linerboards.
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Optimized dimensions for efficient packaging and shipping
Zero Setup Fee
Free Shipping
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Our Happy Clients!
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See our Trustpilot reviews
Trustpilot
"Great experience with Premier Packaging. The quality was exactly as expected, communication was solid throughout, and timelines were met. Overall a smooth, professional process. Would definitely recommend and use them again."
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"The order was done on time and turned out perfect. I will be using them again."
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"We had a great experience working with David on some custom mailer boxes. He was always responsive and helped to ensure the final product met our needs for recyclability. The print quality is unbeatable. When we had an issue with the courier’s handling on delivery, David ensured accommodations were made. We would be happy to work with Premier again in the future."
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"Great Product, Great Pricing. We did a custom box and it turned out perfectly. Extremely happy with the final product. Thanks David W."
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"The Premier Packaging company did an amazing job with our boxes. The boxes are beautiful and sturdy. David was our rep and he did an amazing job with our order and servicing. Thank you!"
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"I am extremely impressed with my experience! The quality of the product exceeded my expectations, and the production time was incredibly fast. Once we perfected the artwork, the ordering process was simple and smooth. I was also blown away by the outstanding customer service that Zack provides. He always responds very quickly to my requests, is extremely helpful, and ensures everything is perfect. Highly recommend!"
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"David was excellent to work with. I received my custom size and designed boxes within a week of ordering them and they look and feel great. Whenever I had a question David, my sales representative was very responsive and always took the time to call me and ensure that my question was answered to the best of his ability. Can’t thank them enough for the quick turnaround. The quality of the product was also impressive considering how fast it arrived to my door! Would highly recommend them to anyone looking to get custom-made boxes! Look forward to working with them in the future!"
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"Got my package in time for my event thank you!"
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"Alex was so helpful and answered all my questions and concerns in a timely manner. He made the experience a reassuring one for someone who was quite fearful of the unknown as a first time customer. Will definitely recommend."
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Google
"Premier Packaging delivered exactly what we were looking for. Quality work, clear communication, and everything arrived as promised. Smooth process from start to finish — highly recommend and would absolutely work with them again."
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"We had a great experience working with David on some custom mailer boxes. He was always responsive and helped to ensure the final product met our needs for recyclability. The print quality is unbeatable. When we had an issue with the courier’s handling on delivery, David ensured accommodations were made. We would be happy to work with Premier again in the future."
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"SO FAST and SO HELPFUL!!! We absolutely love our custom cigarette packages. Everyone was so fast to respond, creative with the design, and the end product was so wonderful they all sold out in 1 day!!! Reordering now!!"
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"The Premier Packaging Group did an excellent job of making our boxes. David was professional, responsive and fulfilled our order very well. TY!!"
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"The Premier Packaging has been a great company to work with! Customer service, prices, timeliness and quality of the products have all been fantastic. I'll continue to work with The Premier Packaging for more custom boxes! -Byron, Treehouse Cannabis Company."
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"Great Product, Great Pricing! Highly Recommend!"
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"Excellent customer service, the product was amazing! I would really recommend The premier packaging for creative projects."
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"The company does professional affordable work and provides quick service!"
Read moreFrequently Asked Questions
A: Yes. We size them based on your product's length, width, and thickness, including the space the bubble lining occupies.
A: A poly mailer is a single film layer. A poly bubble mailer adds a bubble lining for cushioning.
A: Yes. We can print your logo, brand colors, patterns, and messaging on the mailer.
A: Pricing depends on size, quantity, artwork, and print coverage. We quote each order around its specifications.