Short Answer
Custom bubble mailers are padded shipping envelopes with a printed outer face, an air-bubble lining, and a peel-and-seal strip. Teal Packaging prints them in full color and cuts each to your dieline, from 50 units. Production runs from about 7 business days after proof approval, complex or high-volume orders taking longer, plus 2 to 5 business days US delivery.
What Is a Custom Bubble Mailer?
A custom bubble mailer is a flexible shipping envelope with three parts: an outer face that carries your printed artwork, an air-bubble lining that cushions the contents, and a peel-and-seal adhesive strip that closes the pack without tape. It ships flat items in a soft parcel instead of a rigid box.
The build suits shipments where the contents are not fragile but the presentation still matters:
- Apparel, accessories and other soft goods
- Subscription and monthly sends
- Books, print media and small electronics
- Promotional sends and sample shipments
Teal supplies the printed mailers, and its West Chicago, Illinois warehouse handles kitting, assembly, pick-pack, storage and ship-to-recipient when you want the packed parcel to leave without touching your own space.
What Size Should a Custom Bubble Mailer Be?
There is no stock size to pick from. Every custom bubble mailer is cut to your dieline, so the size is made to your product rather than the other way around. Send the dimensions of what you are shipping with your quote request and the free dieline design service builds the mailer to them.
If you are deciding between a soft mailer and a box, run both through the box size and dimensional weight calculator first. Carriers bill on billable weight, not on what the parcel weighs on a scale, so the shape you choose changes the postage line before it changes anything else.
How Are Custom Bubble Mailers Printed?
Printing is full color, and it can run edge to edge across the face. Every order includes a digital proof before anything prints and 2 revision rounds, so artwork, logo placement and copy get corrected on screen rather than after the run.
Across Teal projects the finishing range includes foil stamping, embossing, debossing, spot UV, soft-touch coating, die-cuts and windows, specified per project. Inks are soy and water-based. On brand color: send your color references with the artwork and the digital proof is where you confirm what the press will produce, inside the 2 included revision rounds.
Bubble Mailer or Corrugated Box?
The choice is structural. A mailer conforms to soft contents and closes with a strip; a corrugated box holds a fixed shape around contents that need it. Both are cut to your dieline and both start at the same minimum.
| Custom bubble mailer | Custom corrugated box | |
|---|---|---|
| Build | Printed outer face, air-bubble lining, peel-and-seal strip | E-flute or B-flute corrugated board, folded and glued |
| Suits | Soft goods, apparel, books, small accessories | Rigid, fragile or multi-item shipments |
| Closure | Peel-and-seal strip, no tape | Tape, tuck or crash-lock |
| Sizing | Cut to your dieline | Cut to your dieline |
| Minimum | From 50 units | From 50 units |
Teal's wider material range covers kraft paperboard at 300 to 400gsm, white SBS at 14 to 18pt, corrugated E-flute and B-flute, rigid chipboard at 1.5 to 2.5mm, mylar, tin and vinyl, with FSC-certified and recyclable options available by specification. If a project turns out to need a rigid format instead, the same quote can cover it.
What Do Custom Bubble Mailers Cost, and How Do I Order?
Custom projects start from 50 units, and specialty rigid formats start from 100 or more. Volume pricing starts from $0.44 per unit and every project is quoted to its own spec, so the number depends on size, material, print coverage and quantity.
- Send your product dimensions, quantity and artwork through the quote request form.
- Free dieline design builds the mailer to your dimensions.
- Approve the digital proof, using up to 2 revision rounds.
- Production runs from about 7 business days after proof approval, with complex or high-volume orders taking longer. Express and economy options are available.
- US delivery adds 2 to 5 business days, and US shipping is free.
To handle material before you commit, order the free sample kit for $19.99 shipping, which is credited toward your first custom order. Questions on spec go to (224) 546-8325 or info@tealpackaging.com. Ready-priced items sit in the online shop with per-unit pricing at each quantity break.
Packing, Storing and Shipping Your Mailers
Printed mailers are one half of a send. If the parcels also need to be packed and dispatched, Teal fulfillment covers kitting, assembly, pick-pack, storage and ship-to-recipient out of the West Chicago, Illinois warehouse. Recurring sends map to subscription box fulfillment, and one-off campaigns where each mailer goes to a different address map to ship-to-recipient fulfillment. For multi-item packs that need assembling before they ship, see kitting services and pick, pack and ship. If you are speccing paperboard alongside mailers, the paper weight chart converts gsm to points.
Frequently Asked Questions
What is the minimum order for custom bubble mailers?
Standard custom projects start from 50 units. Specialty rigid formats carry the higher 100-plus minimum. Products listed in the online shop carry their own per-product minimums.
What sizes do custom bubble mailers come in?
There is no fixed size list. Each mailer is cut to your dieline, so the size is built around what you are shipping. Send the dimensions of your product with your quote request and the free dieline design service builds to them.
How long do custom bubble mailers take?
Production runs from about 7 business days after proof approval, with complex or high-volume orders taking longer. US delivery adds 2 to 5 business days on top. Express and economy options are available, so tell the team your in-hand date when you request the quote.
Can I get a sample before ordering?
Yes. The sample kit is free and ships for $19.99, and that shipping cost is credited toward your first custom order. It is the practical way to handle material and print quality before committing to a full run.
Are recyclable or FSC-certified options available?
FSC-certified and recyclable material options are available by specification, and printing uses soy and water-based inks. Name the requirement on your quote request so it is written into the spec rather than added later.
Can you match my brand colors?
Printing is full color, and your color references should go in with the artwork. The digital proof is where you confirm how the press will reproduce them, and 2 revision rounds are included to adjust before the run starts.
How to Order Custom Bubble Mailers
Ordering custom bubble mailers is simple:
- Submit a quote request with your dimensions, quantity, and design references
- Receive quote guidance within one business day
- Send your artwork or work with our design team (free dieline + 2 revision rounds)
- Approve the digital proof and production begins
- Standard production runs from about 7 business days after proof approval; complex or high-volume orders take longer
