A die cut mylar bag is a laminated barrier pouch cut to a custom outline, such as a bottle, a leaf, a character or your logo, instead of the usual rectangle. TBPB makes them custom with no minimum order, and if you bring a written quote for the same specs, we beat it under our price-beat guarantee.
What the die cut actually changes
The film, the barrier and the closure are the same as a standard mylar bag. A printed PET outer layer, a foil or metallized middle layer and a heat-sealable inner layer give the bag its resistance to light, oxygen and moisture. The die is a steel blade formed to your outline, and it trims the sealed pouch into the shape. What you get is a bag that is recognizable from across a room before anyone reads the label.
Simple shapes work better than detailed ones
This is where most first designs go wrong. A bag has to be sealed all the way round, so thin arms, narrow necks and sharp inside corners become weak points or dead space. A bottle silhouette with a wide base, a leaf with a rounded tip or a rounded-corner badge all cut cleanly. A spiky starburst or a figure with skinny legs usually does not. If you are unsure whether your outline will work, send the artwork and we flag the trouble spots before it goes to the die.
Sizing around the product
Because the shape tapers, the usable cavity is smaller than the outline suggests. Tell us what goes in the bag, whether that is flat edibles, loose flower, cookies or small accessories, and how much of it, and we work backwards from the product to the bag size. Shapes that narrow at the top need a straight section for the zipper, so the zipper does not follow a curve.
Print, finish and compliance
Print both sides in CMYK or Pantone, with a matte or gloss finish, and add a tear notch, hang hole or clear window if the shape allows. If the bag holds food, hemp, cannabis or supplements, the labeling and contact-material rules are yours to confirm with your own regulatory adviser. We print the artwork you supply.
- Outline: any custom shape that can be sealed all the way round
- Film: laminated PET outer, foil or metallized barrier, heat-seal layer
- Options: zipper, tear notch, hang hole, window
- Print: both sides, CMYK or Pantone, matte or gloss
For the simplest custom outline, see circle mylar bags. If you need the product to stand up on a shelf, stand up mylar bags are the better structure, and custom shaped mylar bags covers related outlines. Everything is listed in the mylar bags collection.
A word on timing and testing. A new shape needs a die, and the first bags off it are worth inspecting properly: check how the zipper sits, how the seal runs through narrow sections, and whether the printed edge lines up with the cut. That is why ordering a very small run first is a sensible way to approve a shape before committing to a larger one. With no minimum order, you can do exactly that and adjust the outline once, rather than discover a problem across a full pallet.
Send us your outline artwork, what goes inside, and the quantity, even if it is one bag. We check that the shape can be sealed and cut, then quote it.
Frequently asked questions
What is a die cut mylar bag?
It is a mylar pouch trimmed to a custom outline instead of a rectangle. The shape can be a bottle, leaf, animal or your logo. The film layers, barrier properties and zipper are the same as a standard bag. Only the cut line changes.
Is there a minimum order for die cut mylar bags?
There is no minimum order. You can order a single bag to check the shape or thousands for a full run. Each order is quoted for its own size, film and print, and if you hold a written quote for the same specs elsewhere, we beat it.
What shapes work best?
Simple outlines with rounded corners and a wide base cut and seal cleanly. Thin limbs, narrow necks and sharp inside corners become weak seals or wasted space. Send your artwork and we will mark any areas that may cause trouble before the die is made.
Does a custom shape reduce how much fits inside?
Usually yes. The bag is sealed all the way round and tapers with the outline, so the usable cavity is smaller than the outside shape suggests. Tell us what goes in and how much, and we work backwards from the product to the bag size.
Can die cut bags have a zipper and window?
Yes, if the shape has a straight section near the top for the zipper and room for a clear window. A window lets light in, so it reduces barrier protection in exchange for visibility. A tear notch and hang hole can also be added.
Who is responsible for labeling and compliance?
You are. We print the artwork you supply and do not write regulatory copy or certify contact suitability. For food, supplements, hemp or cannabis, confirm required labels and material requirements with your own regulatory adviser before ordering.
More Mylar Bags
See the full Mylar Bags range, or explore related options with no minimum order and our best-price guarantee:
