Poly mailer vs bubble mailer vs rigid mailer: which one to ship in
Ship soft goods that cannot break in a poly mailer, small items that need light cushioning in a bubble mailer, and flat items that must not bend, such as prints, photos and cards, in a rigid mailer. At Tria poly mailers start at 200 units (10 to 12 business days after proof), bubble mailers at 250 (8 to 10 days) and rigid mailer envelopes at 500 (8 to 10 days). None of the three resists crushing, so anything with corners or glass belongs in a box.
Head-to-head comparison
| Poly mailer | Bubble mailer | Rigid mailer | |
|---|---|---|---|
| Protects against | Rain, dirt, prying eyes | Light knocks and scuffs | Bending and creasing |
| Does not protect against | Impact, crushing | Crushing, sharp corners | Impact, crushing |
| Best for | Apparel, soft goods, textiles | Cosmetics, jewelry, small accessories | Prints, photos, cards, documents |
| Build | 2.5 or 3 mil polyethylene, peel and seal | Poly outer, 3/16 in bubble lining, self-seal | Paper front, chipboard back, peel and seal |
| One to three color flexo, outside | Up to four colors, flexo or digital, outside | Full CMYK on the exterior | |
| Tria minimum | 200 units | 250 units | 500 units |
| Lead time after proof | 10 to 12 business days | 8 to 10 business days | 8 to 10 business days |
| Returns strip | Optional second strip | Optional second strip | Not standard |
Poly mailers
A poly mailer is water resistant, light and nearly flat, which is why it dominates apparel. Choose 2.5 mil for tees, scarves and knits, and 3 mil for anything with an edge that might punch through, such as a boxed candle or a bag with hardware. It comes in matte white, matte black or natural gray film, with an optional tear strip and a second strip for returns. It gives no crush protection, so a fragile item needs a box first.
Bubble mailers
A bubble mailer adds a 3/16 in bubble lining inside a poly shell. It suits lipsticks, compacts, small jewelry boxes and phone accessories. We make five standard sizes from 4 by 8 to 14.5 by 19 inches, rated to about 2 to 3 pounds depending on size. The padding absorbs a knock, not a squeeze, so glass and anything with corners that can crush goes in a box. The shell resists everyday moisture but is not a sealed waterproof barrier.
Rigid mailers
A rigid mailer envelope has a stiff chipboard back built into the envelope, so flat goods arrive flat. Size it with about a quarter inch of clearance on each side so the item slides in without catching. For a signed print or anything irreplaceable, test your item in a sample first.
Which one costs least to ship
All three are light and thin compared with a box, which is the main reason mailers ship cheaper. The poly mailer is usually the lightest. The bubble mailer adds bulk from the lining, and the rigid mailer adds the weight of the chipboard. Carriers price by weight and, above certain sizes, by dimensions, so run your real packed weights and sizes through your own carrier's rate card. Our carrier rate sizing guide covers how box dimensions change the bill.
When to move up to a box
Move to an apparel mailer box or a kraft mailer when the item has corners, is glass, needs to arrive without creases, or when the opening is part of the brand. A box costs more to ship but saves the returns that a crushed parcel causes.
Sustainability claims on mailers
Recycled-content film is available on request for both poly and bubble mailers, with documentation for the exact film supplied with the quote. Polyethylene film can usually go to store drop-off, not curbside, so a recycling claim on a poly mailer needs that qualifier. If a plastic-free soft mailer matters more than padding, our compostable mailer is the flat, unpadded option; read the compostable mailer certifications guide before printing any compostable claim.
This is packaging guidance, not legal advice.
Questions people ask
Is a poly mailer waterproof?
It is water resistant: the polyethylene film keeps rain and dirt out in transit. The seams and closure are not a sealed waterproof barrier, so it is not rated for submersion. For most apparel shipping, water resistant is all you need.
Can I ship glass in a bubble mailer?
We would not. The bubble lining absorbs a light knock but not a crush, and glass breaks from pressure as often as from impact. Ship glass in a mailer box with a foam, molded pulp or corrugated insert.
Which mailer is cheapest to ship?
Usually the poly mailer, because it is the lightest and thinnest. Bubble and rigid mailers add weight and bulk. Carriers charge by weight and, above certain sizes, by dimensions, so check your own carrier's rates with real packed weights.
Can these mailers be printed on the inside?
Poly and bubble mailers print outside only; the bubble lining is on the inside. Rigid mailers print on the exterior as standard, and interior print can be quoted as an add. For branding on opening, a printed tissue sheet or thank you card works in any of them.
I want a plastic-free soft mailer. Which guide should I read?
Read our compostable mailer certifications guide next. It explains what the certifications mean and what you can print. This guide compares poly, bubble and rigid mailers; that one covers the compostable alternative to poly.