Mailer Size Charts

A mailer size chart should help you avoid both loose packaging and packages that are too tight to protect the item.

A practical way to choose mailer sizes

Start by measuring the item after folding or wrapping it the way it will actually ship. Then add enough room for closure, thickness, protection, and easy packing.

Product group	Likely package family	Main sizing risk
T-shirts and light apparel	Poly mailer.	Fold thickness and easy closure.
Hoodies and bulky soft goods	Large poly mailer or box.	Overstuffing the mailer and stressing the seal.
Small boxed items	Bubble mailer or small box.	Corner crush and loose movement.
Fragile items	Box with protection.	Too little void fill or too small a box.
Flat paper goods	Rigid mailer or flat mailer.	Bending, moisture, and edge damage.

Before buying a case of mailers

• Measure packed items, not just bare items.
• Check seal room after folding or wrapping.
• Keep one test package for each common item type.
• Avoid buying bulk sizes that only fit one rare product.

Related sections

Last updated: April 30, 2026. Product links may be added only where they fit the page and are clearly disclosed.