Choosing the right poly mailer size is the easiest way to protect your product and cut your shipping cost. Too big and you pay for wasted space; too small and your item barely fits. Here's how to pick the right size every time.
Poly mailer size chart
Poly mailers are measured width x length (usable space is slightly smaller because of the seal and flap). These are the most common sizes and what they're made for:
- 6 x 9 in — jewelry, accessories, cosmetics, phone cases, single small items.
- 7.5 x 10.5 in — a folded t-shirt, socks, small apparel.
- 9 x 12 in — one to two shirts, leggings, soft goods.
- 10 x 13 in — a hoodie or sweater, thicker apparel.
- 12 x 15.5 in — multiple garments, small blankets, bundled items.
- 14.5 x 19 in — bulky apparel, pillows, larger soft goods.
- 19 x 24 in — oversized and multi-item orders.
How to measure
Lay your product flat, measure its width and height, then add about an inch to each side so it slides in without straining the seams. Unlike a box, a poly mailer should hug the product — you want a snug fit, not empty space.
Why size affects your cost
Poly mailers weigh almost nothing, so most orders ship at the lowest weight-based postage rate. The savings come from not over-sizing: a right-sized mailer keeps your package thin enough to qualify for the cheapest carrier tiers and avoids dimensional-weight surcharges.
Pick your material
Standard white or gray 2.0–2.5 mil film handles most apparel and soft goods. Step up to a heavier mil for rough handling, or choose a 100% recycled option if sustainability matters to your brand.
Ready to order? Browse all poly mailer sizes, or get wholesale & case pricing if you ship in volume.