Custom Bubble Mailers

Sleek Packaging. Serious Protection.

Our custom bubble mailers are perfect for shipping apparel, accessories, books, tech gadgets, cosmetics, and more.

Protective Yet Lightweight Materials

We use premium-grade materials that reduce shipping weight while maximizing impact and protection.

• Poly bubble mailers – Water-resistant, tear-proof, and lightweight
• Kraft bubble mailers – Eco-conscious with a natural, rustic texture
• Padded interiors – Built-in bubble lining to cushion fragile products
• Tamper-evident seal – Secure adhesive for worry-free delivery

Custom Sizing to Fit Your Product Perfectly

Whether you’re mailing T-shirts or tech accessories, we tailor every bubble mailer to your exact dimensions.

• Small sizes for jewelry, USBs, or samples
• Medium mailers for cosmetics, books, or gadgets
• Large sizes for apparel, merch kits, or subscription bundles
• Available in flat or gusseted formats

Brand It Your Way

Make every shipment a statement. Our custom bubble mailers let your brand shine from mailbox to unboxing.

• Full-color exterior printing
• Metallic or pastel color options
• Logo and tagline placement
• QR codes for instant brand connection
• Inside-printing available on select materials

Add-Ons That Boost Experience

Small touches make a lasting impact.

• Custom thank-you notes or inserts
• Discount coupon sleeves or loyalty cards
• Branded return address stickers
• Printed tracking instructions or social handles

3Ps of Custom Bubble Mailer Packaging

Presentation

Custom printing helps your brand stand out in a sea of plain packaging.

Preservation

Interior bubble wrap ensures protection against rough handling.

Protection

Water-resistant outer layers and tight seals keep contents safe and dry.

Why 5000+ Brands Trust Custom Boxes Lab

From startup boutiques to national DTC brands, we’ve helped businesses ship smarter.

• No minimum order quantity
• Free design setup & dieline creation
• Fast U.S.-based production & delivery
• Eco and non-toxic ink printing
• Responsive support from packaging specialists

Let’s Create Your Custom Bubble Mailers

Get secure, stylish, and brand-consistent packaging for every shipment. To get cost-effective packaging boxes without compromising on quality, you can contact us at (469) 649-8706 or email us sales@customboxeslab.com

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.