Custom Apparel Mailers
A poly mailer is the lightest way to send soft goods and the least forgiving surface to print on. It stretches, it creases, and it is the first thing a customer sees.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the poly mailer structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures apparel mailers actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
A mailer is fed portrait, so the proportions are not free
Mailers run through fulfilment and postal equipment on their long axis, which means the height needs to sit roughly between 0.8 and 2.2 times the width. A very wide, short bag or a very tall, narrow one will not feed or seal reliably. Pick dimensions inside that band and let the garment fold to fit, rather than the other way round.
The mistake that costs a print run
Full-coverage dark print on a bag that will be stretched
Poly film stretches around the contents, and a solid dark print shows every crease, every stretch mark and every scuff from the sorting network. Lighter grounds with a bold mark survive the journey far better. If a dark bag is the brand, expect it to arrive looking handled.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom apparel mailers
What size mailer fits a folded t-shirt?
Around 10 × 13in for a single tee. Fold the garment the way it will actually be packed and measure the block; a mailer that is slightly generous seals better than one that is tight.
Poly or bubble mailer for clothing?
Poly for soft goods with nothing rigid in them. Bubble as soon as there is a buckle, a zip, a hard tag or an accessory that could be dented or could work through the film.
Why do my printed mailers look scuffed on arrival?
Film stretches over the contents and dark solid coverage shows every mark from the sorting network. A lighter ground or a bolder, simpler mark hides the handling far better.