Die-cut mylar bag
3.5 mil mylar, custom die-cut shape1,000 minimum · 12 to 14 business daysA die-cut mylar bag is a stand-up or flat pouch cut to a custom outline instead of the standard rectangle, so the finished bag is shaped like a leaf, a character, a bottle, or whatever silhouette the brand wants rather than trimmed square. We run them on 3.5 mil mylar from 1000 units, ready in about 12 to 14 business days after proof.
When to choose it, and when not to
Choose a die-cut shape when the bag's outline is part of your brand's shelf presence and a standard rectangle pouch would look generic next to it, and you have the volume to support the extra tooling a custom die line needs.
Choose a standard stand-up pouch instead if budget or a smaller first order matters more than a custom silhouette, since a die-cut shape carries its own tooling cost and a higher minimum than our standard rectangular bags.
Specifications
| Film | 3.5 mil mylar, high-barrier laminate |
|---|---|
| Shape | Custom die-cut silhouette, any outline within standard die-cutting tolerances |
| Closure | Heat-sealed with a resealable zip track |
| Up to 10 color gravure or digital, full coverage | |
| Barrier | Light and moisture resistant, holds scent |
| Minimum | 1000 units |
| Lead time | 12 to 14 business days after proof |
| Prototype | On request; timing confirmed in your quote |
| Sizes we run | 3 x 5 in (small novelty shape) 5 x 8 in (standard product size) custom dimensions to your die line |
Materials that suit it
Questions people ask
Is there a tooling cost for the custom die shape?
Yes, a one-time die charge applies to cut your specific outline. We quote that separately from the per-unit bag cost once we have your shape.
How intricate can the die-cut outline actually be?
Fairly intricate curves and points work fine. Very thin sharp points or narrow necks in the outline can be fragile in the finished bag, so we'll flag it in the proof if your shape needs a small adjustment for durability.
Does the zip track still work on an irregular shape?
Yes, the resealable zip runs along the top of the bag the same way it would on a rectangle. The die-cut shape is the outer silhouette, not the seal itself.
Can I test a small batch before committing to 1000 units?
The 1000-unit minimum reflects the die-cutting setup, so we can't go lower on a first run. A structural prototype before the full order lets you check the shape and fit without committing to the full print run.
Will the shape hold up in shipping, or is it more fragile than a rectangle?
A well-designed die line holds up fine for normal handling. We review your shape before cutting and will point out any spot that's genuinely thin or likely to tear.
Can the same die be reused for reorders?
Yes, once the die is cut it's kept on file for reorders. You only pay the tooling charge once unless you change the shape.
How is a die-cut mylar bag different from the child resistant mylar bag?
The die-cut bag is about shape: a 3.5 mil high-barrier film cut to a custom outline, a leaf, a character, a bottle, with a resealable zip track and print by gravure or digital. It starts at 1,000 units in 12 to 14 business days after proof, and the die carries its own tooling cost. The child resistant mylar bag is a standard-shape barrier pouch with a child-resistant zipper tested to 16 CFR 1700.20, with test documentation available on request, from 200 units in 10 to 14 business days. A child-resistant zipper is not part of the die-cut spec, so if your state requires child resistance, start with the CR bag.
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Ready to price your die-cut mylar bag?
Send the size and quantity for a quote and a dieline, usually within one business day. Your digital proof follows, usually within one business day of your artwork. Design help and the Swatch Book of materials are free.