Poly Bubble Mailers

Poly bubble mailers are shipping envelopes with a water-resistant polyethylene outer film and a bubble-cushion lining, printed with your brand. TBPB makes them with no minimum order, and the price-beat guarantee means we will beat a written quote for the same specs.

Why the poly outer matters

The outer film is what separates this style from a paper-faced padded envelope. Polyethylene sheds rain, wipes clean and does not scuff to a grey mess when a parcel slides across a conveyor. It also takes color well, so a flat brand color or a bold pattern keeps its punch all the way to the doorstep. The trade-off is that film is harder to recycle through standard curbside programs than paper, and some customers care. If that matters to your audience, say so when you ask for a quote and we can discuss alternatives, including the padded mailer option.

Where the bubble lining helps and where it stops

The lining is there for small impacts. Think of it as a buffer for scuffs and light bumps, not armour. Poly bubble mailers work for cosmetics in tubes, small accessories, phone cases, printed goods, makeup palettes already inside a box, and apparel items that benefit from a little cushioning. They are not the answer for glass, for anything that can snap, or for items with sharp corners that will press through both layers. A rigid product wants its own carton first, and for heavier loads a mailer box is the better route.

If you are shipping soft goods only, such as T-shirts or leggings, you probably do not need the lining at all. A plain poly mailer is lighter and a good deal cheaper to post, and we will say so rather than sell you cushioning you will never use.

Sizing, sealing and printing

Choose the size by the thickest part of your product, using usable inside dimensions. Allow for the flap and the adhesive strip, and leave a little room so the seal closes flat without strain. A mailer packed so tightly that the film stretches will split at the seam in transit.

The seal is a peel-and-press adhesive strip. We can print on the outer film in full color, so a logo, a repeat pattern or a full wrap are all possible. Keep important text away from the seam and the strip, and avoid very fine hairline details, which can fill in on film.

• Polyethylene outer film with a bubble-cushion lining
• Self-seal adhesive strip
• Printed on the outside in your colors
• Several sizes per order, no minimum order on any of them

Also see our more general custom bubble mailers if you want to compare the two ranges side by side.

Packing it so it arrives well

How you pack matters as much as what you pack in. Slide the product toward the closed end, then press the air out of the lining by hand before you peel the strip. That keeps the mailer flat, which helps it sort cleanly on carrier belts and stops it popping under the weight of other parcels. For items with hard corners, wrap them once in tissue or a thin paper sheet first, so the corner cannot rub through the lining. Do not overfill; if the sides bulge, go up a size. A mailer that closes flat with no tension on the seal almost always outlasts one that was squeezed shut, and it looks tidier when your customer takes it off the doorstep.

It also pays to test one before a full run. Pack your heaviest item, drop it from waist height onto a hard floor, and see what the corners look like.

How to start

Send your product dimensions and quantity, even if it is only a single mailer. TBPB lays out the artwork area, confirms the size and returns a quote. You do not need to decide on a final design before asking, because rough artwork is enough to price it.

Frequently asked questions