Custom shaped mylar bags (also referred to as die cut pouches) are among the quickest methods of transforming a product from looking like it belongs on the dollar store shelf to making it look and feel like a premium product; without, of course, making any changes or alterations to the product itself! A standard rectangle design will accomplish what you want, however, a custom silhouette will create a lasting impression.
If you are currently considering ordering custom shaped Mylar bags, you likely wish to have three things:
1. An accurate understanding of their costs
2. What minimum order quantity (MOQ) you can indeed expect to facilitate your budget
3. A clean and simple list of the steps to take to order without any headaches or mistakes
Within this guide you will find all three items, however, the guide contains very specific information that the suppliers you are working with want to know so they’ll quote you a final price.
A custom shaped die cut mylar bag is simply a pouch that is not made from material that is cut into the basic rectangle shape. Instead, the bag will be produced in an exact outline die cut to the silhouette you provide to the manufacturer. Manufacturers refer to them as "die cut pouches" or "die cut Mylar bags".
Some common usages include:
* Digitized silhouette (logo) bags
* Character or mascot outlines
* Product-shaped bags (e.g. bottle, fruit, cartridge, flame, badge)
* Retail hang-hole bags for peg hooks (for retail display)
* Limited drops, collaborations or special editions
Even though the shape of your custom shaped Mylar bag is going to be the most important aspect of your order, appropriate barrier film can be used; therefore, it should also have the option of featuring a high barrier, zipper closure, tear notch and/or be child-resistant.
View custom shaped mylar bag designs.
Custom shaped Mylar pouch prices are not calculated solely by size multiplied by quantity. Custom shaped Mylar pouches are priced based upon both the size of the product and the complexity of its construction.
The Price can be affected by:
Larger bags are going to be more costly because they use more materials. Thicker laminations and higher barrier films will also be more expensive. Also, if you want to protect your product against moisture, oxygen, and/or light you will have to pay for more material. This also means a better shelf life for the product and fewer problems with the product.
Heavy printing (complete coverage) + colour matching and large solid printing areas will increase costs and the lead time for production because the printing proof is longer to make.
Adding printing finishes or enhancements to your packaging will add to your cost and require extra production time. Adding finishes such as matte, gloss, soft touch, metallic, and holographic, and adding spot finishes will add to the price of producing each unit. The longer the production run or set-up time for the run, the more the production run costs would increase.
Any feature added will add to the cost of your bags. Some examples are:
- Resealable zipper
- Tear off notch
- Hang hole
- Rounded corners
- Window (see through area)
- Child resistant zipper
- Valve (for coffee bags)
If your shape is custom, a custom die will be needed for your shape, the more complex the cutting of the shape (Complexity of Cutting/Shaping), will affect the printing machine's registration.
The more bags manufactured, the less cost per bag.
To get an accurate quote send:
- Dimensions
- Quantity
- Rough sketch (example) of the shape of your bag. Measurements will help for visual support.
Most companies (manufacturers) have a MOQ. Please contact the manufacturer for a quote on your specific needs.Compared to stock bags, suppliers often impose larger MOQs on custom-shaped Mylar bags because of the initial setup and die-cutting costs they must cover before producing your order.
In the real world, the MOQs for your custom-shaped Mylar bags typically fall within three groups:
In real life, MOQs land in three buckets:
If you are unsure, ask the supplier two questions up front:
That will save you a week of back-and-forth.
By asking those questions upfront, you can eliminate approximately one week of back-and-forth communication with your supplier.
When ordering shaped Mylar bags, follow this simple ordering guide so you will not make any mistakes when ordering:
- Size of the product you will package in the bag.
- Headspace you require above the product fill line.
- Upright in a printed bag needing a gusseted bottom.
The majority of custom-shaped bags are actually manufactured in the following similar structures:
- Stand Up Pouch (gusset): offers the best look on retail shelf presence.
- Flat Pouch: thinner profile/less expensive option.
- Hang Hole Pouch: ideal retail hanging option.
After selecting your structure type; fit your desired profile to the type of bag you'll create.
A die cut outline looks cool, but it can compromise the strength of your seals.
To ensure that you create seals with integrity and keep the zipper on your design aligned, you need to:
If your shape is incompatible with the closure, you end up with leaks, ripple in your zipper, or an ugly seal at the top of your bag.
Quick rule of thumb: Products that are prone to damage from humidity, air or light should not be compromised on the material.
Choose:
You will need to provide:
If you don’t have a dieline, request one. A competent packaging supplier will typically offer you a template format or create one for you.
Custom die-cut bag orders typically take longer than standard rectangular shapes.
Because of:
- Dieline setup and approvals
- Die-cut accuracy checks
- Print-to-cut alignment quality
When estimating lead time for custom shapes, consider that it will generally take longer for the custom shape to be delivered than for the standard shaped pouch ordered — especially on the first run. Re-orders of the same dimensions will have a shorter lead time since all tooling and specifications have been established and approved.
Before placing your order, consider asking your supplier the following questions. This should help you sound like someone who knows what they are talking about:
- What material structure did you quote and at what barrier level?
- Is your quoted barrier level suitable for my products?
- What is the minimum order quantity (MOQ)?
- How long will it take to complete production of my order after I approve it?
- Will you send me a dieline template or confirm that my dieline is correct?
- What are the acceptable tolerances for cut and printed alignment?
- Will you send me photos of previous die-cut pouches you have produced?
- What is the best order quantity to receive the most cost-effective price break?
If suppliers provide clear answers to your questions, then that’s their indication of being capable of providing quality results.
Many custom die-cut pouch shapes will look fantastic before production but will create a big headache after production.
The following shapes generally produce well:
The following die cut shapes will cause you problems during production:
If you want the outline of your custom die-cut pouch to be particularly unique, ensure that you keep the top portion of the pouch as simple and clean as possible and let the creative detailing extend down into the pouch.
Yes. “Custom shaped Mylar bags” and “die cut pouches” usually mean the same product: a pouch cut to a custom outline instead of a rectangle.
Most of the time, yes. You are paying for die cutting setup and tighter quality control so the print aligns with the cut. The more complex the outline and finishes, the more the price increases.
MOQs vary by supplier, size, and print method, but custom shaped bags typically require higher minimums than standard stock pouches because of tooling and setup.
They can be odor-resistant if they use a high-barrier film structure and the seals and zipper are applied correctly. Smell resistance comes from materials and sealing, not the outline shape.
Yes, but the top section needs enough straight width for the zipper and enough seal space above it. If the shape pinches near the top, zipper alignment becomes harder.
Yes, especially for impulse products. A custom silhouette creates instant recognition and can increase pick-up rate because the bag looks unique from a distance.
A vector dieline is best, usually PDF or AI, showing cut lines, safe zones, bleed, zipper placement, and any windows. If you do not have it, many suppliers can provide a template based on your dimensions.
