How to set up custom mailer artwork.
Mailer artwork goes on a dieline: the front, the back and the seal flap, each with 3 mm of bleed and a 3 mm safe area. Keep text off the welds and out of the band the sealed flap covers, and give 1-color art one solid ink.
Order custom mailers online: poly or bubble, any size: a logo mailer from 500 ($545.70 delivered for 1,000 10″ × 13″ poly mailers, one color) or full color from 5,000 on your own dieline, with an instant 3D proof.
See my priceThe dieline
Every mailer we make has its own dieline, drawn to the exact width and height you choose: the front and the back side by side, and the seal flap on top of the back. On the order page your art goes straight onto it in your browser. Designing in Illustrator instead? The layered dieline for your size is $5 through Stripe: a PDF and an SVG with the cut line, the flap fold, the welds and the adhesive strip on their own layers.
Bleed, safe area and welds
| Spec | Number | Why it matters |
|---|---|---|
| Bleed | 3 mm past every cut line | Backgrounds run out to here, so no film edge shows |
| Safe area | 3 mm inside every cut line and weld | Text and logos stay inside it |
| Side and bottom welds | 8 and 10 mm (poly), 12 and 14 mm (bubble) | Ink can run through them, but small text gets crushed |
| Resolution | 300 DPI at print size, or vector | Lower resolution prints soft; the canvas warns you |
The seal flap
The seal flap folds over the opening and lands on the top of the front, so whatever you print on it reads as a band across the top of the sealed mailer. On the order page you design the flap upright, exactly as it will be seen; the print file turns it the way the factory needs it. The flap’s inside carries the adhesive strip and its peel-off liner, which are never printed.
The sealed flap also covers the top of the front: about 1.3″ on most mailers (1″ on the smallest). Keep logos and text below that band; a background can run right through it.
White ink on colored films
On black, pink, blue and kraft we print a white ink base under your colors, so a red reads red instead of taking on the film’s color. Where there is no ink, the film shows. On white and recycled film no white base is needed.
1-color print
1-color print is one ink: a black logo on white film, or a white logo on black film. Pick one of our standard inks or name a Pantone to match. Give the printer one solid color: on the order page every piece of art you place turns into that one ink, so you see exactly what prints.
Approving your proof
Before you pay you see your mailer in 3D with its flap sealed, and the canvas flags low resolution and art in the danger zones. Your approval is the proof, so check spelling and wording. Our prepress team then checks every approved file for printability and contacts you within one business day if anything can’t print well.
Frequently asked questions
What file types can I upload for mailer artwork?
AI, PDF, PSD, PNG, JPG, SVG and TIFF open right on the dieline in your browser. ZIP, EPS and anything else go to our prepress team, who place it for you.
How much bleed do custom mailers need?
3 mm (about 1/8″) past every cut line. Keep text and logos 3 mm inside every cut line and weld.
Can I print on the seal flap?
Yes. Choose front and back printing and you design the flap upright on the order page; it reads as a band across the top of the sealed mailer.
Do I need a dieline to order?
No. Your mailer’s dieline opens on the order page and you place your art on it there. Designers who prefer to work in their own software can buy the layered dieline for $5.