Custom Air Pillows, Printed for Shipping in Bulk
Turn plain void-fill into a branded unboxing moment. We custom-print your logo, colors and message onto lightweight air pillows that cushion products, block movement, and fill empty space — inflated on demand from flat film rolls.
Your logo, on every pillow
Everything you need to know about custom air pillows
Custom air pillows are inflatable plastic cushions used as protective packaging — the lightweight bags of air you find surrounding products inside a shipping box. They do two jobs at once: they fill empty space so contents can’t shift in transit, and they cushion fragile items against knocks and drops. “Custom” means the film itself is printed with your logo, brand colors, or a message, so the void-fill that used to be an afterthought becomes part of the unboxing experience. For e-commerce brands, subscription boxes, and 3PLs shipping thousands of parcels, custom air pillows turn every order into a branded touchpoint while keeping products safe.
Because they ship flat as film and inflate on demand, air pillows take up almost no storage until you need them, and one roll expands into a large volume of cushioning — which is why they’ve largely replaced foam peanuts and heavy paper for parcel void-fill. The right choice depends on what you’re shipping and how much protection it needs: small parcel pillows suit poly mailers and jewelry boxes, standard pillows handle everyday mixed cartons, and quilted cushion sheets wrap fragile goods like a blanket. This guide covers the pillow formats and sizes, the film types (including recycled-content and biodegradable options), custom-print and material details, how ordering works, and how bulk pricing is structured. If you already know what you need, you can request a custom quote at any point.
A branded air pillow works twice — protection and marketing
Plain clear void-fill disappears into the recycling bin. A custom air pillow printed with your logo does the same protective job while reinforcing your brand at the exact moment a customer opens their order. Whether you ship electronics, cosmetics, or curated subscription boxes, printed air pillows make the inside of the box look as considered as the outside — without adding weight, cost, or a separate packing step.
Brand visibility
Every parcel becomes a branded unboxing moment. Print your logo, tagline, or a thank-you message so your identity carries all the way inside the box.
Real protection
Air-filled cushions immobilize contents and absorb shock, helping reduce damage and returns on fragile and high-value items in transit.
Made to spec
Choose the pillow format, size, film type, and print — from small-parcel cushions to large void-fill, in recycled or biodegradable film, in bulk quantities.
From your logo to your loading dock in four steps
Send your artwork
Share your logo (vector preferred), brand colors, and the pillow format, film type and quantity you need.
We design & proof
We lay out your print across the film, match your brand colors, and send a digital proof for review.
You approve
Confirm the proof and final quantity. Nothing goes to production until you sign off.
We print & ship
Your air pillow film is printed, quality-checked, and shipped as ready-to-inflate rolls or pre-inflated cases.
Air pillow sizes: which format do you need?
Pillow size drives how much space each cushion fills and how well it protects. Small pillows suit poly mailers and small cartons; larger pillows fill oversized boxes fast with minimal material. The sizes below are common industry formats — exact dimensions are confirmed on your quote and depend on the film and machine setup.
Typical pillow footprint by format
Typical footprints of common air pillow formats. Larger pillows fill oversized cartons with fewer units; small pillows conform around compact items.
How to read pillow sizes
- Match the pillow to the box — bigger voids call for larger pillows; tight gaps call for small-parcel cushions.
- Think in volume, not weight — air pillows add almost no shipping weight, so size for coverage.
- Fragile items need cushioning — quilted or bubble formats wrap contents rather than just fill space.
- Buy film on the roll — uninflated film stores flat and inflates on demand at your bench.
Not sure which format fits your parcels? Tell us what you ship and we’ll recommend a spec.
| Format | Best for | Typical size | Primary job |
|---|---|---|---|
| Small Parcel Mailers | Poly mailers, jewelry boxes, small cartons | ~4×4 to 4×8 in | Gap fill |
| Standard Popular | Everyday mixed parcels | ~8×8 in | Void-fill |
| Large Void-Fill | Oversized cartons, light bulky goods | ~8×12 in & up | Fast void-fill |
| Quilted Cushion | Fragile, high-value items | Connected sheets | Wrap & cushion |
| Bubble Air Cushion | Surface protection, full-wrap | On-demand film | Cushion |
Light as air, tough enough to protect the whole box
Air pillows are made from thin, flexible film — most commonly polyethylene — that’s sealed into chambers and inflated with air at the point of packing. That construction is what makes them so efficient: a single roll of flat film expands into a large volume of cushioning, so you store almost nothing and only make the pillows you need. The film is engineered to hold air reliably through handling and transit, resisting punctures and slow leaks so cushions stay firm from your dock to your customer’s door.
Sustainability increasingly drives the film choice. Alongside conventional film, greener options include recycled-content film (up to 50% recycled material, cutting footprint without cutting protection) and biodegradable, bio-based film that’s designed to compost. Because air pillows are mostly air, they use very little plastic per parcel to begin with, and many polyethylene pillows can be deflated and recycled with other soft plastic film where collection is available. You choose the film that matches your brand’s protection needs and environmental goals.
- Polyethylene film — flexible, puncture-resistant, holds air in transit
- Inflated on demand — flat rolls expand to a large volume of cushioning
- Recycled-content film — up to 50% recycled material available
- Biodegradable option — compostable, bio-based film for greener brands
- Low material per parcel — mostly air, minimal plastic used
- Custom-printed — your logo and colors printed across the film
Make the void-fill unmistakably yours
Custom logo printing
Print your logo, text, or a thank-you message across the film in your brand colors so it shows on every inflated pillow.
Pillow format
Small parcel, standard, large void-fill, quilted cushion, or bubble — matched to what you ship.
Film type
Conventional, up to 50% recycled-content, or biodegradable bio-based film for greener packaging.
Size & footprint
From compact gap-fillers for mailers to large-format pillows that fill oversized cartons fast.
Roll or pre-inflated
Order uninflated film rolls for your own on-demand machine, or pre-inflated cases ready to pack.
Bulk quantities
Order by the roll or case in volume, with per-unit pricing that improves as your quantity grows.
Air pillow types and what they’re best at
Different jobs call for different pillows. Here’s the full lineup, from everyday void-fill to greener films and uninflated rolls, so you can match the product to your parcels:
Every format can be custom-printed with your logo. Mix formats across an order to cover your full product range.
How to choose the right custom air pillow
The best pillow comes down to what you ship and how much protection it needs. Use this quick guide to match your parcels to the right format and film.
| What you ship | Recommended format | Film type | Why |
|---|---|---|---|
| Poly mailers & small boxes | Small parcel | Standard / recycled | Fills tight gaps without over-stuffing |
| Mixed e-commerce cartons | Standard | Standard / recycled | Best all-round void-fill value |
| Large, light, bulky goods | Large void-fill | Standard | Fills big cartons with fewer units |
| Fragile & high-value items | Quilted / bubble cushion | Standard | Wraps and cushions, not just fills |
| Eco-focused & premium brands | Any format | Biodegradable / recycled | Greener footprint, on-brand story |
| High-volume in-house packing | Film rolls | Any | Inflate on demand, store flat |
Not sure which fits your operation? Tell us what you ship and your volume, and we’ll recommend a spec with your quote.
One pillow, many shipping jobs
How custom air pillow pricing works
Custom air pillows are priced by volume — typically by the roll or case — and the per-unit price drops as your quantity climbs. Your final quote depends on four things: pillow format & size, film type (standard, recycled, or biodegradable), print colors, and total quantity. Larger runs and simpler artwork bring the unit cost down the most.
Custom air pillow questions, answered
What are air pillows made of?
How do air pillows work for shipping?
Are air pillows better than bubble wrap?
Can you print my logo on the air pillows?
Are air pillows recyclable?
Do you offer biodegradable air pillows?
What sizes do custom air pillows come in?
What’s the minimum order for custom-printed air pillows?
Do I need a machine to use air pillows?
How much protection do air pillows provide?
What’s the typical turnaround time?
Do you ship nationwide?
What artwork format do you need?
How do I get a quote?
Ready to put your logo on every parcel?
Tell us your pillow format, film type, quantity and colors — we’ll send back exact pricing, a proof, and a production timeline. Bulk orders welcome.