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 original 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 high 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 with water-based inks. 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. Contact us to request your ink sample.

Stock Ink Colors

Art Requirements

  • File Format: Vector format required, PDF preferred
  • 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: 0.0625"
  • Vertical Movement Tolerance: 1/4"
  • Horizontal Movement Tolerance: 1/4"
  • No Printing on Flaps or Folds

We have a 25% print coverage maximum. This means your design may not cover more than 25% of the mailer - no flood coating, heavy ink coverage, or full bleeds.

vector versus raster artwork

We require vector format artwork so we can scale designs without losing any detail. Raster images are typically pixelated and these pixels can be visible in the final print. Learn More: Vector vs. Raster

Barcodes & QR Codes

Barcodes are allowed as long as they meet our art requirements and have a bearer bar. QR codes are allowed on all mailers except 100% Recycled Padded Mailers because this mailer's texture has a higher chance of fill-in.


New to mailer printing or have more questions? We are happy to review your design and 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.

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.