Packaging for shirts.
The best packaging for shirts is a custom printed mailer box when presentation matters, such as premium pieces, gifts and drops, and a printed poly mailer for everyday orders, with a 10 × 13 inch poly mailer fitting one folded T-shirt and larger sizes for hoodies and multi-packs. A box adds structure and an unboxing; a poly mailer is light, water-resistant and cheap to ship.
Shirt mailers, priced online: 500 printed 10 × 13 in poly mailers start at $292.30 with a one-color logo, Free US shipping included.
See my priceWhich pack for which shirt
| What you ship | Pack | Size | Starting at |
|---|---|---|---|
| A premium shirt, a gift or a drop | Corrugated mailer box | 12 × 9 × 2 in inside | $353.59 for 100 kraft ($3.54 each) |
| One folded T-shirt | Poly mailer | 10 × 13 in (fits about 9.25 × 12.25 in inside) | $292.30 for 500 white ($0.585 each); $311.45 recycled |
| A hoodie, or two or three tees | Poly mailer | 12 × 15.5 in or 14.5 × 19 in (the larger fits about 13.75 × 18.25 in inside) | $598.15 for 500 at 14.5 × 19 in |
Starting-at prices from our live order pages, checked October 17, 2026: one design, Standard delivery to a US address with Free US shipping built into the price. Your price moves with size, material, print, quantity and delivery speed. Mailers are printed one color on the front.
Fold to fit
A T-shirt folded in thirds lengthwise and then in half comes out at roughly 9 × 11 in and about 1 in thick, which is why the 10 × 13 in poly mailer is our most ordered size. A mailer wraps over its contents, so the thickness comes out of both the width and the length; our mailer size guide walks through the math.
Poly mailer or box?
- Poly mailer: the lowest cost per shipment, light, water-resistant and impossible to crush a shirt in. Choose it for everyday orders.
- Mailer box: holds the fold, protects prints and embellishments, and turns delivery into an unboxing. Choose it for premium pieces, gifts, bundles and launches.
- Both: many apparel brands ship everyday orders in poly mailers and save a printed box for limited drops.
Printing your shirt mailers
Poly mailers come in white, black, pink, blue and recycled film. A one-color logo starts at 500 per design and full color at 5,000. On black film, logos print best in white ink or bright colors over a white base. Want a lower-impact option? Recycled poly mailers use post-consumer content. Production takes as few as 5 business days from artwork approval (up to 15), then delivery takes 25 to 35 days with Standard or 4 to 12 days with Expedited.
Price your mailers on our custom mailers store, or a printed shirt box on our custom boxes store.
Frequently asked questions
What size poly mailer for a T-shirt?
A folded T-shirt fits a 10 × 13 inch poly mailer, which holds about 9.25 × 12.25 inches inside. A hoodie or a few shirts usually need a 12 × 15.5 or 14.5 × 19 inch mailer.
Should I ship shirts in a box or a poly mailer?
A poly mailer for everyday orders: it is lighter and cheaper to ship. A printed mailer box when presentation matters, such as premium pieces, gifts and launches.
What is the minimum order for custom shirt mailers?
At TWO Packaging, 500 per design with a one-color logo, or 5,000 in full color.