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How to Mail a Bubble Mailer

Written by Fasih Rauf, packaging consultant at Dream Custom Boxes.

bubble mailers design
Table of Contents

Bubble mailers have been a trusted packaging option for many businesses when shipping small or lightweight products today. These mailers provide excellent protection for your products, especially when safety is a top priority. However, mailing with a bubble mailer might be challenging if you’re new to this. To help you out, let’s walk through the steps to ensure your bubble-wrapped package arrives safely in the hands of your customers.

What Are Bubble Mailers? 

Before we start, it’s worth it to understand what a bubble mailer is. Bubble mailers, also known as padded envelopes, are a type of shipping envelope lined with bubble wrap for cushioning and protection. They are popular for mailing small, lightweight, and delicate products. Moreover, these mailers offer a more lightweight and compact alternative to shipping boxes while still protecting your products during transit. 

Step-by-Step of Mailing a Bubble Mailer

Here are step-by-step to help you mail your product with a bubble mailer!

Step 1: Measure the Exact Size of Your Product

For sure, you want your product to remain perfect inside the mailer. At the same time, the bubble mailer should not be too small that it tears or bursts during sealing. Here’s what you should do to measure your product’s dimensions:

  • Use a measuring tape to get the exact length, width, and height of your product. 
  • Uniquely shaped products might require larger mailers to accommodate their curves. 
  • Consider using additional packing materials, such as tissue paper or bubble wrap, to protect delicate products.

Step 2: Choose a Bubble Mailer with the Right Size

Do note that bubble mailers come in various sizes. To choose the right size, consider both the outside dimensions (exterior) for shipping costs and the inside dimensions (usable) to ensure your product fits inside.
Have a look at the table below for the sizes of bubble mailers. 

Exterior SizeUsable SizeBest for
12.5 in. x 19 inches12.5 in. x 18 inchesLarge catalogs, toys, clothing, and stationery products
8.5 in. x 12 inches8.5 in. x 11 inchesReports, catalogs, magazines, journals, novels, and hardcover books
7.5 in. x 11 inches7.5 in. x 10 inchesMidsize products, such as DVDs and books
6 in. x 10 inches6 in. x 9 inchesMidsize products, such as CDs and photos
4 in. x 8 inches4 in. x 7 inchesJewelry items and smartphones

Step 3: Pack with Protection

Once you have the right-sized bubble mailer, it’s time to pack your products. 

Here are some tips to pack your product with protection. 

Wrap It

If you’re sending delicate items such as jewelry, action figures, or electronics, consider using tissue paper or bubble wrap to provide extra cushioning. Remember, creating a soft, protective shell for your product will prevent the effects of shocks or bumps that might happen during transit.

Don’t Leave the Extra Space

If there’s extra space within the mailer after wrapping your product, you should not leave it empty. Why? Because that empty space will enable your product to move around, leading to damage. Consider using packing materials, such as packing peanuts, crinkled paper, or air pillows, to fill the gaps.

Seal It

Typically, bubble mailers come with a self-sealing adhesive strip for easy closure. Before sealing, ensure the strip is clean and free of any debris. Then, press the adhesive strip strongly along its entire length to create a tight seal for your product inside.

Step 4: Address and Stamps

Before mailing your bubble mailer, you need to label it with the customer’s address. Also, just as with mailing a letter, you will need to put a stamp (or stamps) on your bubble mailer. 

Get the Proper Stamp

When choosing a stamp, keep in mind that the key factor here is thickness. So, the United States Postal Service (USPS) considers your mailer an envelope if it’s under ¾ of an inch thick. Meanwhile, anything thicker than that will be classified as a package. This difference will surely influence the postage costs you need to pay.

If your bubble mailer qualifies as an envelope and weighs 1 ounce or less, one stamp will be enough. 

Addressing

You will need to write two types of addresses: 

  • The address of your customer
  • The return address (in case of delivery issue)

Step 5: Send Your Bubble Mailers

Done with everything? Now you can mail your bubble mailer safely! Keep in mind that different carriers have varying prices based on the classifications they assign to weights and sizes. The cost to ship a bubble mailer depends on its size and weight, the shipping destination, the shipping carrier, and any additional services. Therefore, you must properly weigh your package and consider the accurate size to minimize the shipping costs. Moreover, you will need to pay more for a far distance.

Step 6: Use Tracking & Insurance

If you believe your product is valuable or want to ensure your customers receive it safely, consider using tracking and insurance. Many shipping services provide tracking numbers that enable you to monitor the progress of your package. Meanwhile, getting insurance can provide financial protection in the event of loss or damage to your product.

Why Use Bubble Mailers? 

Research in 2010 found that packages experience as many as 27 drops or tosses on a one-way shipment. Therefore, your products must be protected during shipping, even if they don’t fall into the category of fragile. Accordingly, a bubble mailer protects smaller products that you may not consider fragile but are still vulnerable to breakage. 

Types of Bubble Mailers

Different products have different characteristics and needs. How can you choose the right type of mailer? The good thing is that there are various types of bubble mailers to choose from. 

What are they?

  • Kraft Bubble Mailers: Made of eco-friendly kraft material, they offer a balance of protection and sustainability. 
  • Padded Bubble Mailers: Feature a layer of bubble wrap to protect fragile and small products during the shipping process.
  • Poly Bubble Mailers: Made from polyethylene film, these mailers are known for their durability and water resistance.
  • Custom Bubble Mailers: They can be personalized with a company logo and design, enhancing brand visibility and customer engagement. To get custom bubble mailers, you can contact a reliable manufacturer, like Dream Custom Boxes.
  • Self-Seal Bubble Mailers: Featuring a peel-and-seal closure, these mailers provide convenient and secure packaging.
  • Anti-Static Bubble Mailers: Designed for shipping electronic products, these mailers protect against damage caused by static electricity.
  • Tamper-Evident Bubble Mailers: These mailers feature perforations or special seals to ensure the security of sensitive products.
  • Transparent Bubble Mailers: Featuring a transparent window, these mailers provide easy product visibility.
  • Metallic Bubble Mailers: These mailers offer a sleek, metallic look and enhanced protection against moisture, light, and odors.

Depending on your product and packaging needs, you can choose the ideal bubble mailer that best suits your requirements. 

Summing Up

Undoubtedly, bubble mailers have been a trusted packaging option for many businesses when shipping small or lightweight products today. These mailers provide excellent protection for your products, especially when safety is a top priority. Hopefully, the steps we provided here help you mail your bubble mailer and ensure your bubble-wrapped package arrives safely in the hands of your customers. 

Happy mailing!

FAQs

What are bubble mailers? 

Bubble mailers, also known as padded envelopes, are a type of shipping envelope lined with bubble wrap for cushioning and protection. They are popular for mailing small, lightweight, and delicate products. 

Why should we choose bubble mailers? 

Your products must be protected during shipping, even if they don’t fall into the category of fragile. Accordingly, a bubble mailer protects smaller products that you may not consider fragile but are still vulnerable to breakage. 

How to choose the right size of a bubble mailer? 

To choose the right size of a bubble mailer, consider both the outside dimensions (exterior) for shipping costs and the inside dimensions (usable) to ensure your product fits inside. 

How much does it cost to mail a bubble mailer? 

The cost to ship a bubble mailer depends on its size and weight, the shipping destination, the shipping carrier, and any additional services. 

Can I track my package in a bubble mailer? 

Yes, many shipping services provide tracking numbers that enable you to monitor the progress of your package.

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Fasih Rauf

Fasih Rauf is a packaging consultant at Dream Custom Boxes with 4+ years of experience helping e-commerce and retail brands select the right custom packaging. He specializes in corrugated and paperboard materials, structural box design, print finishing techniques, and packaging cost optimization. His work has helped businesses reduce shipping damage, lower dimensional weight charges, and build stronger unboxing experiences. He regularly publishes packaging guides on LinkedIn and Medium.

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