Custom die cut mylar bags manufactured in any shape. Choose foil, kraft, clear, or recyclable barrier films with resealable zippers, hang holes, windows, and degassing valves. Full-color printing, free dieline development, pre-production samples, and fast nationwide delivery across the USA.
Get Your Custom Boxes Designed in Your Desired Shape, Size and Style
Get Your Custom Boxes Printed With Your Desired Artwork And Colors
Get Custom Boxes At Wholesale Prices. Low MOQs. No Die or Plate Charges
| Dimension (L + W + H) | All Custom Sizes & Shapes |
| Quantities | Low Minimum Order Required |
| Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scoring, Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 8 – 12 Business Days, RUSH |
| Shipping | FREE USA |
Die cut mylar bags are high-barrier flexible pouches cut into custom shapes or with functional cutouts contoured outlines, hang holes, handles, or product windows using a purpose-built cutting die. They combine the moisture, oxygen, and UV protection of laminated foil film with shelf-differentiating shape, making them ideal for snacks, supplements, pet treats, coffee, and cosmetics.
Most brands start with stock pouches because they’re cheap and fast. Then the problems show up.
Your bag looks identical to the four competitors sitting beside it on the shelf. Your retailer asks for a hang hole you can’t provide. Your product needs a window, but a standard window position cuts through your artwork. Or you’ve built a brand around a specific silhouette a bone shape for pet treats, a bottle contour for a supplement line and a rectangle simply doesn’t communicate it.
There’s a second, quieter problem: barrier failure. A lot of “custom” pouches sold online are single-layer PE with a metallic print effect. They look like foil. They don’t perform like foil. Six months into a retail cycle, you’re dealing with rancid oils, clumped powders, faded colors, and returns.
Die cut mylar bags solve both issues at once. You get a genuine multi-layer laminate engineered for barrier performance, cut into whatever shape your brand and your retailer require.
Two things are happening in a die cut mylar bag, and it helps to separate them.
The mylar structure. Mylar is BoPET biaxially oriented polyester film. On its own it’s strong and printable but not a complete barrier. Real performance comes from lamination: bonding PET to a metallized layer (VMPET) or true aluminum foil, then to a sealant layer of PE or CPP. That sandwich is what blocks oxygen transmission, water vapor, and light.
The die cut. After printing and laminating, the web is cut with a custom steel rule or rotary die. That die is machined to your dieline, so the finished pouch can be any outline you specify plus any internal cutouts you need.
Custom die cut mylar bags are, in short, the intersection of engineered barrier film and custom tooling. Buying one without the other gets you a pretty bag that fails, or a functional bag that disappears on shelf.
We build the dieline before we quote. A lot of suppliers quote off a rough sketch and discover the problem at the die-making stage. Our team produces a production-ready dieline with correct seal allowances, bleed, and cut tolerance up front, so what you approve is what runs.
Structure recommendations based on your product, not our inventory. A high-oil pet treat, a hygroscopic pre-workout powder, and a whole bean coffee all need different laminates. We spec the film to your shelf life target and fill method not to whatever roll stock is sitting in the warehouse.
Real print control. Digital printing for shorter runs and fast SKU variation; rotogravure for high-volume work where per-unit cost matters most. CMYK plus spot color matching, matte and gloss varnishes, soft-touch, and holographic effects are all available on the same structure.
Pre-production physical proofs. You see and handle the actual bag printed, laminated, die cut before the full run is committed.
Nationwide supply from a single point of contact. We serve food brands, e-commerce sellers, and wholesale distributors across the United States, with one project manager on your account from dieline to delivery.
Straight answers on cost. Custom tooling is a one-time charge, and we tell you what it is before you commit. No surprise line items after the PO.
Stand-up pouches with a K-seal or doypack bottom gusset, flat three-side seal pouches, side gusset bags for coffee, quad seal boxes for structured shelf presence, and flat bottom pouches for maximum face area. Die cut stand up pouches are the most requested format for retail, because the shape reads clearly when the bag is upright and filled.
Film gauges typically run 3.5 mil to 7 mil depending on fill weight, drop-test requirements, and barrier target.
Resealable press-to-close zippers, slider zippers, child-resistant closures, one-way degassing valves for freshly roasted coffee, laser tear notches, hang holes, spouts, and easy-open scoring. Resealable mylar bags are worth the small unit cost increase on any product a customer opens more than once it directly affects repeat purchase experience.
Full-surface printing with logo, nutrition panels, barcodes, batch coding areas, and regulatory copy. Matte and gloss lamination, soft-touch coating, spot UV, cold foil, and holographic film. Printed die cut mylar bags carry color consistently across reorders because we retain your press profile and match to approved standards.
Shelf differentiation that’s structural, not just graphic. A custom shape is recognized from further away than a logo. It’s the single most effective way to break a category’s visual pattern.
Measurable shelf life extension. Correct barrier selection is the difference between a 6-month and an 18-month product. That reduces write-offs, opens up longer retail cycles, and lets you produce in larger, more efficient batches.
Retail compliance without retrofitting. Hang holes, handle cuts, and barcode zones designed in from the start rather than a sticker solution applied later when a buyer asks.
Lower shipping and storage cost than rigid packaging. Flexible packaging bags ship flat, weigh a fraction of jars or tins, and cut both freight and warehouse footprint. For e-commerce brands paying dimensional weight, the savings are immediate.
Faster SKU expansion. Once your tooling exists, launching a new flavor or variant means new artwork on the same die not a new development cycle.
1. Discovery. We take your product type, fill weight, fill method, target shelf life, distribution channel, and quantity. If you’re unsure of the structure, this call determines it.
2. Dieline development. Our team builds the custom shape dieline with correct seal margins, bleed, and cut tolerance, and sends it as a layered file for your designer or we handle the artwork in-house.
3. Digital proof. A 3D render and flat proof for approval. This is where copy, barcodes, and regulatory content get verified.
4. Tooling and pre-production sample. The cutting die is machined and a physical sample is produced. You handle it, fill it, drop it, and approve it.
5. Production. Printing, lamination, curing, die cutting, pouch forming, and inline quality inspection.
6. QC and delivery. Seal integrity checks, dimensional verification, and print consistency review before shipment anywhere in the United States. Typical turnaround runs 10–15 business days after final approval, with rush options available.
Food brands and snack companies needing shape-driven shelf presence. Candy manufacturers running seasonal and limited-edition SKUs. Pet treat brands where contour die cuts communicate the product instantly. Supplement companies requiring foil barrier for oxygen-sensitive actives and CR closures where regulated. Cosmetic brands packaging masks, bath products, and sample sachets. Coffee businesses needing valve-equipped side gusset or die cut stand up pouches. Retailers and private label companies producing house-brand lines at volume. E-commerce brands optimizing for ship weight and unboxing. Wholesale distributors sourcing mylar bags wholesale across multiple client accounts.
What’s the difference between a die cut mylar bag and a regular mylar bag?
A regular mylar bag is cut to a rectangle from standard tooling. A die cut bag uses a custom-machined die, allowing a custom outline shape, hang holes, handles, or window cutouts. The barrier film can be identical the difference is the cut, and the tooling behind it.
Do die cut mylar bags cost significantly more?
There’s a one-time tooling charge for the custom die. Per-unit cost is only slightly higher than standard pouches, and the die is reusable across every reorder and every SKU that shares that shape. Most brands recover the tooling cost within one to two production runs through improved sell-through.
What are the minimum order quantities?
Minimums vary by structure, print method, and format digital printing supports much lower minimums than rotogravure. We confirm the exact MOQ for your specific spec during quoting rather than applying a blanket number that doesn’t fit your project.
Are these bags food safe?
Yes. We use FDA-compliant food-contact materials for food, supplement, and pet applications. Food mylar bags are produced with sealant layers approved for direct contact, and documentation is available on request.
Can I get a custom shape and a resealable zipper together?
Yes. Zippers, valves, spouts, and tear notches are compatible with contour die cuts. The one constraint is that the zipper needs a straight run across the bag width, so we account for that in the dieline.
Are eco-friendly mylar bags actually recyclable?
Recyclable mono-material PE structures are accepted in store drop-off programs where those programs exist. They carry a somewhat lower barrier than foil laminates, so we’ll tell you honestly whether your product’s shelf life target is achievable in a recyclable structure before you commit to it.
Can you match my existing packaging colors?
Yes. Provide Pantone references or a physical sample and we’ll match to approved standards, then retain the profile so reorders stay consistent.
Send us your product details, target quantity, and any artwork you already have. You’ll get a structure recommendation, a production-ready dieline, and a firm quote with tooling costs stated up front no vague estimates and no surprise charges after approval.
Request your free dieline and quote today, or upload your artwork for a same-day structural review.
At Ono Custom Boxes, our Artwork Preparation Guide helps ensure your custom packaging design is print-ready for high-quality results. To get started, submit vector files (AI, EPS, or PDF) in CMYK color mode, with a 1/8 inch bleed and 300 DPI resolution. Convert all text to outlines and keep it at least 1/4 inch from the edges. Review your proof to ensure accuracy before submitting. Following these steps will guarantee your design is perfectly printed on your custom boxes.
The cut line is the outline that marks where your custom packaging will be trimmed. It is typically represented by a solid black line in your artwork file.
The bleed line is the area extending beyond the cut line, usually marked with a green line in your artwork. Typically, a 1/8 inch (0.125") bleed is required to prevent any unwanted white borders.
The crease line, marked by red lines in your artwork, indicates where the box will be folded during production.
Perforation lines, shown as dotted black lines, indicate where the box will have small, evenly spaced holes for easy tearing or separation. These are often used for tear-away sections.
The safety margin, marked by dotted green lines, is the area around the cut line where important elements (such as text, logos, or graphics) should be kept clear.
Need Help with Ono Custom Boxes Consultant? We’re here! We offer a variety of packaging options, from sustainable choices to personalize packaging, all aimed at helping your product stand out. And with our fast turnaround, you can get started without the wait.
Ono Custom Boxes delivers innovative, durable, and affordable packaging tailored to meet your business needs and brand identity.
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