Buyer guides

How to Order Custom-Printed Air Pillows

By the Custom Air Pillows team · June 2, 2026 · 6 min read

Ordering custom-printed air pillows is more straightforward than most buyers expect, but a few decisions early on determine whether the film runs cleanly on your line and looks sharp in the box. Skip a step and you can end up with a gauge that blows out under load or artwork that prints too small to read once the pillow inflates.

Here is the full path from first inquiry to rolls on your dock, laid out step by step.

Step 1: Prepare your artwork

Send vector artwork where possible, ideally with your logo as an EPS, AI, or high-resolution PDF. Because a pillow stretches as it inflates, fine detail and small type can distort, so simpler marks reproduce best. Note your brand colors, and if you need an exact match, provide the Pantone references rather than relying on screen color.

Step 2: Choose the film

Decide between standard, cushioned, recycled, or biodegradable film based on your product and brand goals. Standard film handles most e-commerce void-fill. Heavier or fragile goods point toward a cushioned or quilted grade. If sustainability matters, this is where you pick a recycled-content or biodegradable option, since it changes the quote.

Step 3: Pick size and gauge

Match the inflated pillow size to your typical carton void and the film gauge to your product weight. Small parcels use smaller pillows; large cartons need bigger pillows or more of them. Gauge, measured in microns, sets the film strength. Too thin and it can burst under a heavy load; heavier than you need and you pay for film you will not use.

Step 4: Set the quantity

Quantity drives your per-unit price. Film is sold by the roll with a pillow count per roll, so translate your parcel volume into total pillows and round up to whole rolls. Most buyers order one to three months of supply to earn a bulk break without overcommitting to one artwork.

Step 5: Approve the mockup

Before anything prints, you get a mockup showing your artwork on the pillow at the chosen size. Check the logo placement, the color, and how the design reads once inflated. This is the moment to catch a too-small logo or a color that drifted, because changes after approval mean a reprint.

Step 6: Production and shipping

Once you approve, the film goes to print and production. Typical turnaround runs a couple of weeks depending on quantity and film type, then the rolls ship to your dock ready to load into your inflator.

Pre-order checklist

Step	What to confirm	Why it matters
Artwork	Vector file, Pantone colors	Clean print, accurate brand color
Film type	Standard, cushioned, recycled, or bio	Sets protection and eco claim
Size	Inflated pillow dimensions	Matches your carton void
Gauge	Micron thickness vs product weight	Prevents blowouts and overspend
Quantity	Total pillows, rounded to rolls	Earns bulk pricing
Mockup	Logo placement and color approved	Avoids costly reprints

Choosing for your order

Most first orders start with standard air pillows and move to small parcel air pillows or large void-fill pillows once the size profile is clear. If you are unsure on gauge or film, our team reviews your product and volume before you commit, and the blog has deeper guides on gauge and quantity.

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