Custom T-Shirt Packaging
A t-shirt is a flat, folded rectangle whose pack is judged on two things: whether it arrives uncreased and whether the opening felt like anything. Both are decided by how it is folded.
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 t-shirt packaging 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
The fold is the specification
A tee folded in three is a different footprint from one folded in four, and a heavyweight cotton is nearly twice the thickness of a light one at the same fold. Decide the fold, fold the heaviest garment you sell, measure the block, and size everything from that. Every other decision downstream depends on it.
The mistake that costs a print run
Packing an unpressed garment in a structured box
A box implies care, and a creased shirt inside one reads worse than the same shirt in a bag. If you are paying for a box, the fold and the press have to match it. If the operation cannot press, a mailer sets a more honest expectation and is quicker to fulfil.
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 t-shirt packaging
What size mailer fits one t-shirt?
Around 10 × 13in for a folded mid-weight tee. Heavier garments and multi-item orders need a size up rather than a tighter fold.
Should t-shirts ship in a box or a bag?
A bag is lighter, waterproof and honest about what it is. A box protects the fold and gives you an interior surface to print on, which is worth it where presentation is part of the product.
How do I stop shirts arriving creased?
Fold consistently, pack tight enough that the garment cannot shift, and use a box if the fold has to survive. A loose garment in an oversized bag creases regardless of what the bag is made of.