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Custom Mylar Envelopes from TheCardboardBoxes are flat, secure, and perfect for small product packaging or shipping samples. Our food-safe Mylar offers strong barrier protection against moisture and air. Print your logo, product info, and brand designs with vibrant inks. Available with tear notches and tamper-evident options. Perfect for samples, sachets, and small retail items. Order Custom Mylar Envelopes from TheCardboardBoxes with bulk pricing and free design support.
A mylar envelope is a flat, sealed pouch in an envelope format, typically with a peel-and-seal or heat-seal closure. They're used for protecting documents, photographs, cards, collectibles, pharmaceutical samples, and flat physical products from moisture, static, and physical damage.
Custom mylar envelopes take this practical format and add branding, custom sizing, and print options that make them a professional packaging choice for businesses across many sectors.
In packaging terms, a mylar envelope is typically a three-side-seal flat pouch with a closure strip at the open end. The material is usually a polyester film (PET), which may be combined with an aluminium foil layer for additional barrier performance, or used alone for clarity or antistatic properties.
For document and photograph protection, the PET film is often used without foil, creating a clear or slightly silvery envelope that allows the contents to be identified without opening. For more sensitive applications (pharmaceutical samples, moisture-sensitive components), a foil laminate is used.
Mylar envelopes are used for:
Document protection: Archival storage of photographs, certificates, important papers, and printed materials. The polyester film resists moisture, doesn't off-gas acids (unlike some papers), and provides physical protection.
Collectibles packaging: Trading cards, rare stamps, autographed memorabilia, and other flat collectibles are frequently stored and shipped in mylar sleeves and envelopes to prevent moisture damage and creasing.
Seeds and botanical samples: Seed banks, botanical research organisations, and plant nurseries use mylar envelopes to store and ship seeds because the material preserves viability by controlling moisture.
Pharmaceutical samples: Flat tablet or capsule samples, foil-sealed pharmaceutical materials, and medical device samples all use mylar envelope formats.
Marketing and promotional materials: Branded mylar envelopes for sending welcome packs, vouchers, or premium direct mail materials create a distinctive unboxing experience compared to standard paper envelopes.
For electronics and static-sensitive components, antistatic mylar envelopes are available. These incorporate a conductive or dissipative layer that prevents static charge from building up and damaging sensitive electronics during storage or shipping.
Shielding bags (often called Faraday bags) take this further by providing complete electrostatic shielding. These are standard in electronics manufacturing and repair for storing memory chips, motherboards, and other ESD-sensitive components.
For businesses using mylar envelopes as part of their brand communication, custom printing allows the envelope to carry logos, brand colours, messaging, and design elements. Options include:
- Single-colour logo printing for simple branding
- Full-colour design for premium brand presentation
- Bespoke sizing to fit specific documents or products
- Custom closure strips (peel-and-seal, heat-seal, or zip lock)
- Tamper-evident features for security applications
Branded mylar envelopes are used by financial services companies for sending important documents, by luxury brands for sending promotional materials, and by pharmaceutical companies for sample distribution.
Mylar envelopes are made from several material structures depending on application:
- Clear PET: transparent, lightweight, archival-grade for documents and collectibles
- Silver PET: slightly reflective, provides light screening, common for seed and sample storage
- PET/Foil laminate: full barrier for moisture-sensitive products
- Antistatic PET: for electronics; available in pink (antistatic) or metallic (shielding)
- Kraft/PE laminate: natural paper look for eco-conscious applications
The closure method depends on the intended use:
- Peel-and-seal: an adhesive strip protected by a release liner, suitable for one-time use
- Heat seal: requires heat-sealing equipment, used for production environments
- Zip lock: for reusable envelopes that need to be opened and closed multiple times
- Open top: for envelopes that will be heat-sealed by the packer
Minimum orders for plain mylar envelopes start very low (sometimes just a few hundred units) because they're a standard product available from stock. For custom-printed envelopes with bespoke sizing and design, minimums typically start at 500 to 1,000 units.
At TheCardBoardBoxes, custom mylar envelopes are available in a range of sizes and material specifications, with print options from simple logo branding to full-colour design. Turnaround times are fast and the process is straightforward.
| Box Style | Any Style |
| Dimension | Custom sizes and shapes |
| Quantity | 250 - 500,000 boxes |
| Paper Stock | (12pt to 24pt) Cardstock, Kraft, E-Flute Corrugated, Cardboard, Bux-Board, Rigid |
| Printing | CMYK, PMS |
| Coating | Matte, Gloss |
| Finishing | Embossing, Debossing, Foil Stamping, Spot UV |
| Included Options | Die Cutting, Scoring, Gluing, Fold & Perforation |
| Proof | Electronic Proof (flat, 3D mock-up), Hardcopy Proofing (upon request) |
| Turnaround | 5 - 7 Business Days |
| Delivery | FLAT via Courier |
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A quick-drying, water-based layer that shields paper from smudges and grime while being eco-friendly.
This liquid finish cures under UV lights, giving your paper a vibrant, glossy shine.
This glossy treatment applies only to select areas, making images or text dramatically stand out.
This unique finish creates a velvety or suede-like texture under your fingertips.
A transparent ink that safeguards the page or provides subtle gloss, though it may yellow with age.
A thin plastic film bonded to paper for durability, available in shiny or non-glare finishes.
A rugged plastic barrier that stops scratches and wear from frequent handling.
This layer delivers a luxurious smooth feel and exceptional tear resistance.
Offset printing is a high-volume printing technique using metal plates and rubber blankets.
Digital printing is a method of printing directly from digital files to media.
UV printing uses UV light to instantly cure ink onto a wide variety of materials.
It is a process that transfers ink through a stenciled mesh screen onto a surface.
Flexography is a high-speed printing process using flexible plates and low-viscosity inks.
Gravure printing is a high-quality, high-speed intaglio printing method using engraved cylinders.
This method applies heat to bond glittering metallic hues like gold or silver onto paper, creating designs that truly shimmer.
This approach raises the paper from below to form a tactile image you can feel with your fingertips.
This technique indents your design into the paper, producing a striking recessed effect that brings dimension to your work.
This unique foil shifts through a vibrant spectrum of colors like a dazzling rainbow when light strikes it at specific angles.
This glossy clear varnish targets select areas of the page to highlight particular elements with eye-catching shine.
This sleek coating delivers a non-reflective, velvety texture that feels luxurious and enhances readability.
This highly reflective layer bounces back light, amplifying colors to make your print vibrant and dynamic.
Hot foil stamping is a printing method using heat to transfer foils for decoration.
Premium solid bleached sulfate, C1S coated for vibrant prints and superior food safety.
Solid bleached sulfate, double-coated for flawless printing and premium packaging appeal.
Pure uncoated unbleached kraft ensures raw, sustainable strength for authentic eco-packaging needs.
Clay-coated newsboard delivers affordable strength with smooth surface for bold branding.
Bold black kraft exudes premium elegance and robust protection for standout packaging.
100% recycled clay-coated newsboard offers eco-friendly durability and cost-effective packaging solutions.
Rustic natural brown kraft provides authentic, biodegradable strength for sustainable food packaging.
Clean white kraft combines natural strength with bright, recyclable appeal for branding.
Rugged natural kraft corrugated board delivers eco-friendly strength for reliable food transport.
Elegant oyster white corrugated board offers subtle sophistication and sturdy packaging protection.
Smooth kemi white corrugated ensures crisp prints and robust durability for premium shipping.
Bright bleached white corrugated provides pristine appearance with superior strength for branding.
Tall A-flute excels in superior cushioning and shock absorption for fragile foods.
Fine B-flute offers smooth printing surface and efficient collapse resistance for boxes.
Versatile C-flute balances strength, printability, and space efficiency for standard packaging.
Micro E-flute creates sleek, flat profiles with excellent print quality for retail.
Single face flute adds lightweight protection and flexibility for delicate food wrapping needs.
Single wall corrugated flute balances cost and cushioning for everyday food shipping demands.
Double wall flute delivers enhanced stacking strength for heavier food packaging loads.
Triple wall flute provides maximum crush resistance for industrial food transport durability.
It is a type of paperboard with a white clay-coated top side, ideal for luxury packaging.
Grey Chipboard Cardboard is a thick, sturdy material made from recycled content, ideal for luxury packaging.
This material is slim yet robust enough to maintain its form effectively for petite, lightweight boxes and resilient cards.
An excellent balanced option that offers a firm feel and reliable safeguarding for typical gift box varieties.
This dense board has a substantial heft in your grasp and ranks as the top pick for superior, long-lasting luxury packaging.
This exceptionally sturdy and inflexible material suits bigger items requiring additional reinforcement for security.
The densest and most resilient choice on offer, giving it a near-wooden sensation for the ultimate premium goods.
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