Mailer Envelope
- Multiple mainstream sizes are available, including DL, C5, C4 and US #10 standard sizes, alongside bespoke custom dimensions and unique flap styles.
- A wide range of paper stocks can be selected, such as plain white wood-free paper, durable brown kraft paper, matte/gloss coated art paper and waterproof tear-resistant synthetic paper.
- CMYK full-color and Pantone spot color printing are supported to print brand logos, contact info, slogans and graphics on both single and double sides.
- Optional practical upgrades include self-seal adhesive strips, transparent PVC address windows, privacy security tint, easy-tear perforations, barcodes and QR codes. Premium decorative finishes cover foil stamping, spot UV, embossing/debossing and lamination for better texture and durability.
- Custom mailer envelopes effectively boost brand recognition while protecting letters, documents and goods during transit. They fit office mailing, online retail delivery, promotional mailshots and sample delivery.
Customization options
- Customized logo
- Customized packaging
- Graphic customization
Description
Key Features:
Standard Sizes
- DL Envelope (110mm × 220mm): Ideal for folded A4 letters, invoices, statements and promotional flyers
- C5 Envelope (162mm × 229mm): Perfect for unfolded A5 documents and half-folded A4 sheets
- C4 Envelope (229mm × 324mm): Full-size envelope for unfolded A4 documents, brochures and certificates
- US #10 Envelope (4.125” × 9.5”): Standard business size for formal office mails and customer correspondence
- Custom Size & Shape: Fully bespoke dimensions, custom flap designs and die-cut outlines to fit unique packaging and mailing needs
Material Options
- Premium White Wood-Free Paper (100–120gsm): Smooth surface for sharp printing, lightweight and cost-effective for daily business mailing
- Brown Kraft Paper (120–600gsm): Sturdy, tear-resistant and eco-friendly, perfect for rustic branding, e-commerce shipping and sustainable business styles
- Matte / Gloss Coated Art Paper (150–600gsm): Delivers vibrant color performance, ideal for high-end branded and marketing-focused envelopes
- Heavyweight Cardstock: Rigid and anti-bending, specially made for important documents, certificates and flat product shipping
- Waterproof Synthetic Paper: Water and tear-proof material for long-distance logistics and harsh transit environments
Functional & Premium Custom Options
- Self-Adhesive Peel & Seal: No tape required, providing fast, clean and secure sealing for daily mailing
- PVC Window Cutout: Clear transparent window to display internal recipient information neatly
- Security Tint Lining: Anti-see-through inner coating to protect confidential documents and private data
- Easy-Tear Perforation: Pre-cut tear strip for convenient and clean envelope opening
- Variable Data Printing: Custom QR codes, barcodes and sequential numbering for logistics tracking and batch management
- Custom Flap Styles: Straight flap, triangular flap, deep wallet flap and personalized shaped flaps
Printing Colors
- Single Black Printing: Economical and clear for standard office and formal business envelopes
- Full CMYK Color Printing: Rich and vivid colors for brand logos, artwork, patterns and marketing designs
- Pantone (PMS) Spot Color Printing: Ensures precise, consistent brand color matching across all batches
- Single-sided and Double-sided printing available for all sizes
Special Finishes & Techniques
- Matte / Gloss Lamination: Adds water resistance, scratch resistance and overall durability for long transit times
- Soft-Touch Lamination: Delivers premium velvet texture for high-end brand packaging
- Foil Stamping: Gold, silver and rose gold metallic finishes to highlight logos and key brand elements
- Spot UV Coating: Creates glossy contrast on matte surfaces to enhance visual hierarchy
- Embossing & Debossing: Adds tactile textured details for upscale customized envelopes
- Precision Die-cutting & Neat Folding: Ensures tidy edges, accurate sizing and flat finished appearance
Typical Use： Custom printed mailer envelopes are widely used for business correspondence, corporate letter delivery, invoice and statement mailing, e-commerce order packaging, direct mail marketing, promotional flyer distribution, product sample shipping, holiday greeting mail, legal document delivery and daily office postal services.
Turnaround：Standard production time is 3–5 business days after digital proof approval. Rush expedited service is available for urgent orders. Envelopes with complex finishes, window cutouts and variable data printing require extended lead time.
Packaging：Finished envelopes are securely packed with shrink wrap for bulk orders. Custom kraft carton packaging is optional for large batches to prevent crushing and deformation during transportation and storage.
Custom Designs：All custom sizes, layouts and shapes are acceptable. Print-ready AI and PDF vector files with embedded fonts are preferred. All images must be provided at a minimum of 300 DPI to ensure sharp, high-quality printing results.
MOQ：Low minimum order quantity starting from 100 pieces for standard printed envelopes. Custom windows, special die cuts, foil and spot UV finishes require a higher MOQ. Large volume orders are eligible for tiered wholesale discounts.
FAQs
What are custom printed mailer envelopes?
Custom mailer envelopes are fully personalized shipping and mailing envelopes used to ship products, invoices, letters and marketing materials. We support custom printing of brand logos, slogans, contact details and patterns on envelopes to upgrade brand exposure while protecting contents during transit. Multiple paper stocks, sizes and finishing options meet regular mailing, e-commerce shipping and business office mailing demands.
What standard envelope sizes do you provide?
We offer widely used mainstream dimensions:
- DL Envelope: 110mm × 220mm, fit standard folded A4 letters, invoices and statements
- C5 Envelope: 162mm × 229mm, holds unfolded A5 documents and folded A4 papers
- C4 Envelope: 229mm × 324mm, accommodates full unfolded A4 paperwork
- US #10 Business Envelope: 4.125” × 9.5”, mainstream American office mailing size
- Custom Sizes: Bespoke dimensions for thick parcels, product samples, small gift shipments and special mail needs. Custom die-cut envelope shapes are also supported.
What paper material choices are available for mailer envelopes?
- Standard Offset Paper: 120gsm–300gsm white wood-free paper for daily office mailing of letters and bills, lightweight and cost-efficient.
- Thick Kraft Paper: 120gsm–600gsm brown kraft stock, sturdy and tear-resistant, ideal for eco brands and rustic-style e-commerce shipping.
- Premium Coated Art Paper: 150gsm–600gsm matte/gloss coated paper, delivers bright printing effects for branded marketing envelopes.
- Waterproof Synthetic Paper: Water-proof, tear-proof material suitable for outdoor delivery, rainy transportation and long-distance logistics.
- Heavyweight rigid cardstock can be selected for rigid document mailers to prevent bending.
What color modes work for mailer envelope artwork?
CMYK four-color printing is available for colorful logos, photos and complex artwork. Pantone (PMS) spot color printing guarantees identical brand colors across all envelope batches for corporate brand uniformity. Single black printing is a budget-friendly option for simple text-only business envelopes. Both single-sided and double-sided printing are supported. All RGB files must be converted to CMYK before submission to avoid printed color distortion.
What bleed and safe zone requirements apply to envelope designs?
A minimum 3mm bleed is required on all four edges of envelope files, including flap areas. Bleed eliminates unwanted white borders after trimming and die-cutting. All critical content such as addresses, logos, barcodes and QR codes must stay 3mm inward from trim lines and fold lines. Minor position shifts may happen during folding, cutting and gluing; the safe zone prevents important design elements from being trimmed or covered by folds.
Which file formats are acceptable for printing?
AI and PDF vector files with all fonts embedded are the most recommended formats. All pictures, logos and patterns must be 300 DPI or higher at actual print size. Low-resolution images cause fuzzy text, blurry barcodes and poor overall printing quality.
What custom functional add-ons can be added to mailer envelopes?
Multiple practical custom features are optional:
- Self-adhesive peel-and-seal strips for quick, secure sealing without extra tape.
- Security tint inner printing to block sensitive address and document content from being seen through thin paper.
- Die-cut windows with transparent PVC film to display recipient addresses inside.
- Perforated tear strips for easy envelope opening.
- Sequential numbering, barcode and QR code printing for logistics tracking.
- Custom printed inner lining for high-end business mail.
What special finishes can upgrade mailer envelopes?
Matte lamination and gloss lamination enhance scratch resistance and water resistance. Soft-touch lamination creates a velvet premium texture. Spot UV and foil stamping (gold/silver/rose gold) highlight logos for luxury branding. Embossing and debossing add tactile texture to envelope flaps and front panels. Edge painting is available for upscale customized orders.
What are common usage scenarios for printed mailer envelopes?
These envelopes fit e-commerce product shipping, business invoice and statement mailing, direct mail marketing campaigns, corporate business letter delivery, sample distribution, holiday promotional mail, legal document delivery, subscription mailing and retail customer order packaging.
What is the minimum order quantity for custom mailer envelopes?
The minimum order quantity is 100 units for standard plain white/kraft mailers with basic CMYK or black printing. Envelopes with custom sizes, PVC windows, foil, spot UV, security printing or special die cuts require a higher MOQ. Large bulk orders qualify for tiered volume discounts to cut unit costs.
How long is mailer envelope production turnaround?
Standard production lead time is 3–5 business days after digital proof approval. Expedited rush service is available for urgent mailing schedules. Orders with multiple complex finishes, die-cut windows and variable barcode data require extended production time.
What packaging is used for finished envelopes?
Finished envelopes are packed with protective shrink wrap in bulk. Custom eco kraft outer boxes can be arranged for large-volume orders to avoid crushing during shipping and storage.
Do you support custom flap styles?
Yes. Common flap types include regular straight flaps, triangular economy flaps, deep wallet flaps and pointed diagonal flaps. We also support fully customized flap shapes and sealing methods tailored to your mailing habits.
