What's the best way to ship clothing to customers?

For apparel over roughly $30 AOV, a printed mailer box is the winner — it protects the garment, doubles as an unboxing surface, and drives repeat purchase rates that a plain polybag cannot. Below $30, a branded poly mailer is a fair compromise between cost and brand feel.

Poly mailer vs printed mailer box — which is better for apparel?

Poly mailers are cheaper (a few cents each) and lighter to ship, but they read as generic. Printed mailer boxes cost more per unit yet lift repeat-order rate and social-share rate in nearly every apparel A/B test we've seen from US DTC brands.

Do you need tissue paper inside a clothing mailer?

For premium apparel — yes. Branded tissue and a sticker seal turn a shipping event into an unboxing moment. For basics or high-volume value tiers, plain tissue or no tissue at all is fine — save the spend for the outer box.

What size mailer box works for folded t-shirts and hoodies?

A standard 10×8×2" or 11×9×2" mailer fits a folded t-shirt. Hoodies need roughly 12×9×3" or 13×10×3". Add half an inch of clearance so tissue and inserts don't cause the lid to bow.

Are mailer boxes worth it for apparel margin?

Yes — at 500+ units per run the per-unit cost of a printed mailer typically lands within a couple of dollars of a branded poly mailer, and the repeat-rate uplift often covers the difference on the second order.

Can mailer boxes be printed on the inside for unboxing?

Yes — inside-print (also called "reverse-tuck reveal") is one of the highest-impact unboxing upgrades for apparel. A brand story, a size chart, or a bold pattern on the interior turns opening the box into a social-share moment.

Best Packaging for Mailing Clothing

By the Custom Box Printing Editorial Team · February 11, 2026

If you're a US-based clothing brand shipping orders from a Shopify store, an Etsy shop, or a small warehouse, the packaging you reach for affects three things customers actually feel: how the product arrives, whether they share the unboxing, and whether they remember your brand on the next order. Here's what apparel founders are actually using in 2026 — ranked by use case.

1. Polybag (the cheapest option)

Generic polybags from a roll cost a few cents each. They protect from moisture, weigh almost nothing (cheap shipping), and stack flat for cheap storage. The cost: zero unboxing experience, no brand surface, and an unmistakable "drop-ship" feel. Right for: low-AOV ($20 and under) basics where margin doesn't support anything fancier.

2. Printed poly mailer

Same form factor as a polybag, but printed with your brand on the outside and (often) the inside. Costs roughly $0.30–$0.80 per piece in custom-print short runs. Big lift in brand impression vs plain poly. Easy to tear open. Most major DTC apparel brands ship in printed poly mailers — Allbirds, Buck Mason, Marine Layer. Right for: $40–$100 AOV apparel that ships solo or in pairs.

3. Printed mailer box (corrugated)

A rigid corrugated box with a self-locking lid, printed full-color outside and (optionally) inside. Per-unit cost is higher — typically $1.50–$3.50 for short runs — but the unboxing impact is dramatically better. Customers photograph these. They show up on TikTok and Instagram. Repeat-customer rates lift measurably when the first order arrives in a printed mailer instead of a polybag — multiple DTC brands have benchmarked 15–25% higher 90-day repeat purchase after switching. Right for: $80+ AOV, gift-able product, anything with a brand story you want customers to share.

4. Custom rigid box (set-up box)

The "luxury" tier — chipboard wrapped in printed art paper, magnetic closure or ribbon pull, EVA foam insert. $4–$12 per unit for short runs. Use for limited-edition drops, high-end accessories, or first-customer welcome kits where the unboxing IS the marketing.

The decision in one sentence

If you're under $40 AOV, use a printed poly mailer. If you're $80+ AOV and want repeat customers, use a printed mailer box. The math on the per-unit cost difference almost always works out in favor of the mailer box once you factor in the lift in repeat purchase rate and the user-generated content you'll get on social.

Custom Box Printing produces custom-printed mailer boxes and poly mailers for US apparel brands — short runs from 100 units, free design support, free US shipping. See our mailer box options or request a free quote.

Ordering custom boxes — common questions

What is the minimum order for custom boxes?

Runs start at 100 units for folding cartons (cosmetic, food, bakery, CBD, mailer), 50 units for rigid setup boxes, and 5,000 units for printed paper (deli, butcher, tissue, kraft, sandwich wrap). No die, plate, or setup fees at any quantity.

Do you ship custom boxes free in the US?

Yes — standard shipping is free anywhere in the contiguous United States on every order. Rush production (3–5 business days) and expedited shipping are available for an additional fee.

How long does a custom box order take?

Typical timeline is 1 business day for a quote, 1–2 days to approve a free 3D digital mockup, then 7–10 business days for production plus 2–5 business days for free US shipping. Rush production is available on request.

Can I see a sample before I commit to a full order?

Yes — free 3D digital mockup with every quote, and a physical sample on request (refunded on your first order) before you place a production run. You can also design and preview your box live in our free 3D box designer.

What artwork files do you need to start printing?

Print-ready PDF, AI, EPS, or PSD at 300 DPI in CMYK with 0.125" bleed is ideal. Don't have artwork? Our in-house design team builds your dieline and preps files at no cost — just send your logo and any brand references.

Do you charge setup, plate, or die-cutting fees?

No — there are no setup, plate, die, or tooling fees at any quantity. Custom dielines, artwork prep, 3D mockups, and physical samples are all included free with every order.

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