Bubble mailer sizes in North America follow a numbered chart from #000 (the smallest) to #7 (the largest). The numbers are an industry convention, not a brand — a #2 from any manufacturer measures roughly 8.5 × 11 inches. That's why a properly sized mailer from one supplier drops into a packing operation built around another's.
One subtlety catches buyers constantly: listed dimensions can be either the outer size (edge to edge, including the seal flap) or the usable interior. A mailer advertised at 8.5 × 12" outer typically holds about an inch less in usable length. When switching suppliers, always confirm which convention the size refers to — it's the single most common cause of 'the new mailers don't fit.'
The standard chart
These are the eleven sizes we run, matching the industry-standard chart:
- #000 — 4 × 7" — cards, jewelry, small electronics
- #00 — 5 × 9" — phone accessories, cosmetics
- #0 — 6 × 9" — DVDs, small books
- #CD — 7.25 × 7" — optical media, square items
- #1 — 7.25 × 11" — documents, softcover books
- #2 — 8.5 × 11" — letter-size, framed photos
- #3 — 8.5 × 13" — legal documents, apparel
- #4 — 9.5 × 13" — larger books, folded garments
- #5 — 10.5 × 15" — boxed accessories, multiples
- #6 — 12.5 × 18" — apparel, housewares
- #7 — 14.25 × 19" — oversize flats, multiples
Pick by dimensional weight, not by 'it fits'
Carriers bill by whichever is greater: actual weight or dimensional weight (length × width × height ÷ a divisor). A mailer that's one size too large doesn't just waste material — on light items it can push the parcel into a higher billed weight. The right size is the smallest one your product slides into without stressing the seams, with the flap closing flat.
If your product sits between sizes, that's exactly the case for a custom dimension. As a manufacturer we build custom sizes routinely — the setup is a one-time charge that repeat volume amortizes to fractions of a cent.
Quick answers
Are bubble mailer sizes the same across brands?
Effectively yes — #000 through #7 are industry-standard dimensions. Confirm whether a listed size is outer or usable interior; that's where suppliers differ.
What size bubble mailer do I need for 8.5 × 11 documents?
A #2 (8.5 × 11") is the nominal match, but for a stack of pages or anything rigid, a #3 (8.5 × 13") gives the flap room to close flat.
Can I get sizes that aren't on the chart?
Yes — custom dimensions are a standard service for us. You pay a one-time machine setup, quoted upfront, and the per-piece price then tracks the material.
