Honeycomb padded mailers are sold in a fairly standard set of sizes across the Australian market, and knowing that range before you order is what stops you either paying for a mailer with too much spare room or squeezing a product into one that is too tight. This page is the specs and sizing reference for custom honeycomb paper padded mailers, use it alongside the honeycomb mailer overview if you have not decided honeycomb is the right format yet.
What a honeycomb padded mailer actually is
A honeycomb padded mailer is a paper mailing bag with a layer of expanded honeycomb kraft paper built into the lining. The honeycomb structure, hexagonal cells pulled open from a flat sheet, cushions the same way bubble wrap does, by holding a cell of trapped air against the product, except the whole thing is paper, so it is kerbside recyclable with the rest of the packaging and does not need to be separated out before the bin.
Sizes to know when comparing mailers
Australian honeycomb mailer suppliers commonly offer a size run built around these bands, useful as a reference regardless of who you order from:
| Typical size (mm) | Suits |
|---|---|
| 150 x 225 (+40mm flap) | Small accessories, jewellery, cosmetics, phone cases |
| 215 x 280 (+45mm flap) | Books, small homewares, multi-item small orders |
| 240 x 340 | A4 documents and folders, clothing folded flat |
| 265 x 380 | Larger books, boxed cosmetics, mid-size electronics accessories |
| 300 x 405 (+40mm flap) | Multi-item orders, larger homewares, small appliances |
| 360 x 480 (+40mm flap) | Bulkier or multi-item orders, larger apparel |
The flap allowance matters as much as the body size, it is what gets folded over and sealed, and a mailer with too little flap is awkward to seal cleanly by hand or by machine.
Choosing the right size for your product
- Measure the product at its largest realistic dimension, not its packaging-free size, include any inner box or wrap.
- Leave minimal spare room. A honeycomb mailer protects by cushioning contact, not by giving the product room to move, so a snug fit performs better than a loose one.
- Check the flap folds over cleanly without needing to be forced, this is a sign the size is right for the fill.
- If your order sizes vary, stock two sizes rather than one oversized mailer for everything, this keeps both protection and cost under control.
Specifying the rest of the mailer
Size is the starting point. The other decisions that shape a custom honeycomb mailer are covered in depth on their own pages:
- Self-seal closures, for one-motion sealing at the pack bench.
- Tear-strip opening, for a customer-friendly unboxing and easier returns.
- Reinforced construction, for heavier or sharper-edged products.
- Compostable options, where a verified compostability claim matters more than standard recyclability.
- Custom branding and print, to make the mailer part of the unboxing experience.
- How ordering a custom run actually works, from spec to delivery.
How Carewell Group helps
Carewell Group is an Australian packaging manufacturer and supplier. We specify honeycomb padded mailers to your product’s real dimensions rather than pushing you toward a single stock size, and can advise on closure type, board weight and material based on what you are actually shipping. Compare against the alternative in padded mailers vs mailing boxes.
Carewell can meet all your packaging needs for your business. Talk to our expert and we will work to your required MOQ. Call +61 (02) 8760 1491 or request samples and a sizing review.
Frequently asked questions
What sizes do honeycomb padded mailers come in?
Common Australian sizes run from around 150 x 225mm up to 360 x 480mm, each with a flap allowance for sealing, sized to fit anything from small accessories to bulkier multi-item orders.
How do I choose the right size?
Measure the product at its largest realistic dimension and choose the smallest mailer it fits into with the flap still folding over cleanly, minimal spare room is better protection, not less.
Do I need one size or several?
If your order sizes vary meaningfully, stocking two mailer sizes protects products better and controls material cost more than using one oversized mailer for everything.
Sources
- Australia Post, parcel size and packaging guidelines: auspost.com.au
Written by Alif Vasaya, digital and content strategy, Carewell Group. Carewell Group is an Australian packaging, food packaging, tape, industrial safety and 3PL supplier serving all of Australia. Last updated 17 September 2026.