Use case · Apparel
Best packaging for shipping apparel and soft goods
Apparel ships best in lightweight, low-DIM-weight packaging. Most t-shirts, hoodies, leggings, and accessories don't need a box — a poly mailer with branded tissue paper protects the item, lowers shipping cost, and gives an unboxing moment without adding pounds of dimensional weight.
Use this kit to route between poly mailers, inner protection, and finishing touches like thank-you stickers and return mailers.
Outer Mailer
A poly mailer is the lightest, lowest-cost outer for soft goods. Tear-resistant, water-resistant, and dense to pack on the pick line.
Inner Protection
A 2 mil poly bag keeps the garment clean and dry inside the mailer; tissue paper adds a branded reveal without adding weight.
Finishing & Returns
Thank-you stickers seal the tissue and lift unboxing. A return mailer or extra poly mailer in the package reduces friction on exchanges.
Apparel packaging FAQ
What is the best mailer for apparel?
A 2.5 mil poly mailer is the standard for apparel ecommerce. It is light, water-resistant, tear-resistant, and lowers dimensional weight versus a box. Use a heavier 3+ mil poly mailer for denim, outerwear, or multi-item orders.
Do I need a poly bag inside the mailer?
It is optional but recommended. A 2 mil poly bag protects the garment from moisture and ink transfer if the mailer gets damaged in transit, and it gives a cleaner unboxing reveal under tissue paper.
Should I include a return mailer?
Including a flat return mailer or an extra poly mailer in the order reduces return friction and is a common practice for apparel brands with high exchange rates. Use the DIM Weight Calculator to check the cost impact before adding one.