Cheapest Way to Ship Without a Box
Save money with poly mailers, padded envelopes, and creative packaging alternatives
How can I ship without a box?
Shipping without a box using poly mailers or padded envelopes saves $2-5 per shipment by reducing weight and eliminating dimensional weight charges. USPS First-Class and Ground Advantage work with flexible packaging. Soft goods, clothing, documents, and non-fragile items ship safely in poly mailers at significant cost savings.
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| Carrier | Service | Price | Delivery Time | |
|---|---|---|---|---|
| USPS | 1 lb in box (12x9x4) | $7.50 | 2-5 days | |
| USPS | 1 lb in poly mailer | $5.90 | 2-5 days | Cheapest |
| USPS | 8 oz in padded envelope | $4.50 | 2-5 days | |
| USPS | Clothing in poly mailer | $4.50-$5.50 | 2-5 days | |
| USPS | Documents in flat mailer | $3.50-$4.50 | 2-5 days |
1 lb in box (12x9x4)
1 lb in poly mailer
8 oz in padded envelope
Clothing in poly mailer
Documents in flat mailer
* Prices shown are discounted ShipWave rates. Actual rates vary by exact dimensions, weight, and origin/destination.
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Why Box-Free Shipping Saves Money
Boxes add cost in multiple ways:
1) Box weight (4-12 oz) adds to shipping cost
2) Box dimensions trigger dimensional weight charges with UPS/FedEx
3) Box purchase cost ($0.50-$2 per box)
4) Void fill materials to prevent movement
A 12 oz item in a 12x9x6 box could cost $9 to ship, while the same item in a poly mailer might cost $5.50 - a 40% savings.
Types of Box-Free Packaging
Poly mailers: Waterproof plastic envelopes, ideal for clothing and soft goods. Cost $0.10-$0.30 each.
Padded mailers: Bubble-lined envelopes for semi-fragile items. Cost $0.25-$0.75 each.
Rigid mailers: Stay-flat cardboard for documents and photos. Cost $0.50-$1.50 each.
Paper mailers: Eco-friendly kraft paper alternatives. Cost $0.20-$0.50 each.
When to Use Boxes vs Alternatives
Use poly mailers for: Clothing, fabric, soft goods, shoes (bagged), non-fragile items, books with corner protection.
Use padded mailers for: Electronics accessories, jewelry, small fragile items, cosmetics.
Keep using boxes for: Glass, ceramics, multi-item orders, heavy items over 5 lbs, premium/gift products, items requiring cushioning on all sides.
Pro Tips to Save More
Size poly mailers correctly
Use the smallest mailer that fits your item with 1-2 inches extra for sealing. Oversized mailers waste material and can fold awkwardly.
Double-bag liquid-adjacent items
Cosmetics or items that could leak should be placed in a sealed poly bag inside the mailer to prevent damage.
Reinforce corners on rigid items
Books, frames, or flat items in mailers benefit from cardboard corner protectors. A $0.10 protector prevents $20 damage claims.
Consider weather exposure
Poly mailers are waterproof but contents aren't. For items that shouldn't get wet, use an inner poly bag inside paper mailers.
Frequently Asked Questions
- Yes, all major carriers accept poly mailers, padded envelopes, and other flexible packaging. Requirements: secure closure, address label visible, and item protected adequately.
- Usually yes, by $1.50-$4 per shipment. Poly mailers weigh 0.5-1 oz vs 4-12 oz for boxes, and create smaller dimensional profiles.
- Clothing, fabric, soft goods, shoes (in dust bags), documents, books (with corner protection), non-fragile accessories. Avoid box-free for glass, ceramics, and electronics.
- Standard poly mailers (LDPE plastic) are recyclable at store drop-offs but not curbside. Eco-friendly alternatives include recycled content, paper mailers, and compostable options.
- Fold clothing neatly, place in appropriately sized poly mailer, press out excess air, seal securely, and apply shipping label. For premium items, add tissue paper wrap.
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