Custom Padded Paper Mailers for Small, Delicate Goods

What are padded paper mailers?

A padded paper mailer is a kraft envelope with a cushion built into the wall. The outer sheet is paper, and a second layer of shaped paper sits against it.

That inner layer is honeycomb paper or fluted paper. Neither one uses plastic film, so the whole mailer is a single material.

It closes with a peel and seal flap. Think of it as the all-paper answer to a bubble mailer.

What size padded paper mailer do I need?

Mailers are sized by flat outside width × length. The padding and seams use up space, so the usable pocket is smaller than the sheet.

Measure your item's length, width and thickness. Add the thickness plus about 1/2 in of margin to both the width and the length.

A trade paperback measuring 5.5 × 8.5 × 0.8 in usually fits a 7 × 10 in mailer. Unsure? Send the item measurements and we will suggest a size.

Our step-by-step guide to measuring covers the method in full.

Honeycomb or fluted paper lining?

Honeycomb paper is a net of small cells that opens out into a springy pad. It hugs curved items such as small bottles, pouches and ring boxes.

Fluted paper has parallel ridges, a bit like corrugated board. It resists bending, so it suits journals, planners and other flat goods. It also shrugs off pokes from sharp corners.

Tell us what you ship most often. We will point you to the lining that fits, and you can ask for a different one on the next run.

Can I print on padded paper mailers?

Yes. The kraft outside takes plain, one color or two color print. Full color CMYK is available for bolder artwork, and print can go on the front and the back.

A black logo on natural brown kraft looks clean and practical. A bright all-over color stands out on a porch or in a stack at a mailroom.

Leave the center of the front clear for the shipping label. Put your return address on the back or the flap, and keep fine text near the edges, because the padded face is slightly uneven.

You can try your logo placement in Design Your Box before we send the proof.

What mistakes should I avoid with padded mailers?

The biggest one is choosing by sheet size alone. A 9 × 13 in mailer will not hold a 9 × 13 in item, because the lining takes room.

Another is sending glass or ceramics. Those belong in a box with an insert and void fill.

The third is overstuffing. A bulging mailer strains the seal and can split at the bottom. If an item barely fits, move up one size instead of forcing it.

When is a box a better choice than a padded mailer?

Pick a box for heavy, rigid or breakable goods. A padded mailer absorbs light knocks but cannot stand up to a crushing load from other packages.

For mugs, candle jars or bottles, see our mailers made for fragile items. They pair a corrugated box with inserts that hold the product still.

Padded mailers do win on speed. There is nothing to fold or tape, and they take very little shelf space.

Do padded paper mailers help keep shipping costs down?

Often, yes. A thin padded mailer weighs little, so many orders ship at a lower rate than the same item in a box. Check each rate's size and thickness limits before you commit.

Choose the smallest mailer your product fits in. An extra inch on every side can bump an order into a higher rate. Our guide to cutting shipping costs goes deeper.

How do I order custom padded paper mailers?

Send the flat size, lining type, outer color, print and quantity. If you are unsure of the size, send the item measurements instead.

Pricing starts from $0.30 a box, and the exact figure arrives in your quote by email within one business day. Free layout help and a free design proof come before printing. You can request your quote online.

After you approve the proof, production takes 4–6 business days. Shipping is free and tracked, and it takes 2–3 business days to any US address.

What if my padded mailers arrive damaged or misprinted?

Spot a misprint, a torn seam or another defect? Email us photos within 10 days of arrival. We will reprint the mailers or refund you.

Open one bundle as soon as the order lands. Check the print, the seal strip and the padding on several mailers, then store the rest flat and dry.

Reach us at info@ordercardboardboxes.com, on WhatsApp, or by phone at (503) 461-4788, Monday to Friday, 9 am to 6 pm Eastern.