Custom Mailer Artwork Guidelines


Design custom mailers with ease. Start here with our guidelines which serve as an overview of our post-production printing parameters. We have a real, live human proof your artwork prior to production to ensure your vision is captured into a beautifully finished product.


Use our downloadable template to place and size your artwork to your specifications. Use your artwork or your designed template as your art file when placing your order.

Looking for templates for our 50% Recycled Bubble Mailers? These mailers are available for custom printing at volumes starting at 25,000+ units. At these volumes, you have access to custom dimensions, branding in up to seven colors, and full edge-to-edge flood coats. Request a high-volume quote.

Ink & Color

We use flexographic printing. Choose from 20 stock ink colors, including black Algae Ink™ for paper mailers. Our standard is 1-color, 1-sided prints.

If interested in any of the below, please contact us.

  • Custom PMS colors
  • Black Algae Ink on poly mailers
  • 2+ printed colors
  • 2-sided prints

Color Matching

It is critical to note that colors may render differently on a digital screen and that colors in your digital proof are only used as reference.

You may request a complimentary physical sample of any stock ink color or a swatch of your custom color on our mailer material. This will provide you with the most accurate representation of the color. Request an ink sample.

Stock Ink Colors

Art Requirements

  • File Format: Vector required, AI preferred, PDF accepted
  • Outline all fonts and embed all supporting files
  • Minimum Font Size (Standard): 12 pt Helvetica
  • Minimum Font Size (Reverse-Out): 14 pt Helvetica
  • Minimum Stroke Size (Standard): 1 pt
  • Minimum Stroke Size (Reverse-Out): 2 pt
  • Minimum Size of Spaces to Avoid Fill-in: 1/16"
  • Minimum QR Code Size: 1.25" x 1.25"
  • Barcodes Must Include Bearer Bar
  • No Printing on Flaps or Folds

We have a 25% print coverage maximum. Your design may not cover more than 25% of the art boundary box on the template - no flood coating, heavy ink coverage, or full bleeds.

We have a 1/4" vertical and horizontal movement tolerance. You may see up to 1/4" of movement in your print.


We require vector format so we can scale designs without losing detail. Raster images are pixelated and these pixels can be visible in the final print.

Barcodes & QR Codes

QR codes must meet our art requirements and be at least 1.25" x 1.25" in size. They are allowed on all mailers except 100% Recycled Padded Mailers because this mailer's texture has a higher chance of fill-in.

Barcodes must meet our art requirements and have a bearer bar. Black is highly recommended for scannability and light colors are not permitted.

Lead Time

Lead time is the estimated time to process your order for shipment and does not include transit time.

For branded orders, lead time begins after artwork proof and, if applicable, ink swatch approval.

What does this mean?

When you place a branded order, our Design Team reviews the artwork files attached to your order and creates an artwork proof. We then send your artwork proof to you for review and approval. We highlight any adjustments made, emphasize potential print risks, and request additional files or information.

Once the proof suits your design vision and aligns with our printing capabilities, we request your written approval. After we receive your written approval, your lead time begins.

Ship 1,000+ Orders Per Week?

We love working with enterprise brands on unique, high-volume mailer projects. Minimum order quantities and custom capabilities varies by mailer. Learn about our high-volume mailer capabilities.


New to custom packaging or have questions? We are happy to share our experience and thoughts on how to bring your vision to life. We work closely with you during the entire process - from art proof to delivery to your door.