Die Cut Mylar Bags

These pouches are foil pouches cut to a custom outline or brand silhouette, so the package itself becomes part of the branding. A rectangle blends in; a custom shape stops the scroll and the shopper. At Apexio Packaging, we make die cut mylar bags in the USA for snack, supplement, cosmetic and cannabis brands that want packaging with a signature outline. With zero MOQ, free design, a free 3D mockup and free US shipping, you can order one shaped sample or a full run at the same high-barrier quality. Get your free quote and free 3D design proof today – email sales@apexiopackaging.com or call +1 (855) 466-6990.

What Are Die Cut Mylar Bags?

Die cut mylar bags are high-barrier pouches trimmed on precision dies into logos, mascots, product outlines or geometric shapes. A steel die cuts the sealed pouch to your outline while the multilayer PET, foil and PE laminate keeps its barrier intact. The result is a memorable shape that still blocks oxygen, moisture and light and holds a clean heat seal. Custom shapes pair with full-colour print, resealable zippers and windows, so the pouch is distinctive and functional at once.

Which Brands Use Die Cut Mylar Bags

Die cut pouches suit brands that live or die on shelf differentiation. Supplement and nutraceutical lines use shaped pouches to look premium, snack brands cut playful outlines for kids and impulse buys, and cosmetic brands echo a product silhouette. Cannabis and CBD brands use branded shapes with child-resistant closures. Many combine a die cut with edge-to-edge graphics, as in our custom printed mylar bags.

Die Cut Mylar Bag Sizes by Capacity

These pouches are built around your fill weight and outline; the chart shows common capacities.

Capacity	Approx. pouch size (W x H, inches)	Common use
14 g / 1 oz	4 x 6 in	Gummies, samples, single-serve
2 oz	4.5 x 7 in	Snacks, herbs, cosmetics
4 oz	5 x 8 in	Supplements, dried goods
8 oz	6 x 9 in	Larger retail packs
Custom shape	Any outline	Logo or product silhouette

Shape and size are both fully custom, so the outline suits your product while the fill sits snug. Stand-up and resealable shaped pouches are available, as in our resealable mylar bags.

Die Cut Mylar Materials and Film Thickness (Mil)

Film gauge and laminate are chosen for barrier and clean cutting.

Material / structure	Thickness	Best for
PET / foil / PE laminate	3.5-5 mil	High-barrier shaped pouches
White PET / foil / PE	3.5-5 mil	Bright full-colour print
Clear / foil (window)	3.5-4 mil	Shaped pouch with a window
Matte metalised film	3-3.5 mil	Premium soft finish

A slightly heavier gauge holds a crisp cut edge on intricate shapes. Our food-grade laminates support food-contact use; see FDA food-contact guidance for edibles, and we confirm the die and structure on your proof.

Printing Options: Digital, Rotogravure and Flexo

We print these pouches by three methods, chosen by run size, artwork and deadline.

Printing method	Best for	Main strength
Digital printing	Short runs, samples, new SKUs	No plates, fast and affordable
Rotogravure	Large runs, photographic art	Richest detail and colour at scale
Flexographic	Mid-to-large repeat runs	Cost-effective for solid brand colours

Digital suits short shaped runs and new SKUs, rotogravure gives the richest detail across large volumes, and flexo is efficient for repeat brand-colour designs. Send your artwork and quantity, and we recommend the better route free.

Colour Options: CMYK, PMS and RGB

These pouches print in CMYK and match exact Pantone (PMS) brand colours, while RGB stays for on-screen design.

Colour system	Use it for	Note
CMYK	Full-colour art, gradients, photos	Standard four-colour print
PMS (Pantone)	Exact logo and brand colours	Identical shade on every reprint
RGB	On-screen design and previews	Convert to CMYK before printing

CMYK handles full-colour art, and Pantone (PMS) matching keeps your signature colour consistent across reprints. We convert RGB and confirm on the proof; our CMYK, PMS and RGB colour guide explains it simply.

Finishing and Surface Effects

Finishes make a shaped pouch feel as distinctive as it looks.

Finish	Effect	Best for
Matte film	Soft, non-glare surface	Premium shaped pouches
Gloss film	Bright, vivid colour	Playful, colour-forward shapes
Spot gloss on matte	Shine accent on a matte base	Logos and hero art
Foil / holographic film	Metallic or rainbow shine	Extra shelf impact
Clear window	See-through panel	Showing the product

A matte pouch with a spot-gloss logo reads premium, while foil and holographic films add shine to an already eye-catching outline, like our holographic mylar bags.

Features and Functional Add-Ons

Add-ons keep a shaped pouch practical and the product fresh.

Feature / add-on	What it does	Best for
Resealable zipper	Reseals for repeat freshness	Snacks, supplements
Child-resistant zipper	Certified CR closure	Cannabis, CBD, edibles
Tear notch	Easy, clean opening	Single-serve pouches
Hang hole (euro slot)	Hangs on a peg display	Retail merchandising
Clear window	Shows the product	Snacks and dried goods

Resealable and tear-notch options keep shaped pouches easy to use, and a certified child-resistant zipper supports compliant cannabis packaging. Ready to build yours? Get a free quote and a free 3D proof now – email sales@apexiopackaging.com or call +1 (855) 466-6990.

Shape as a Branding Tool

A custom outline turns your pouch into a logo people recognise across a shelf. Because the die follows your artwork, the silhouette becomes a brand asset that a plain bag can never match, while the foil laminate still delivers smell-proof, high-barrier, moisture-and-UV protection. That mix of instant recognition and real freshness is why growing brands invest in a signature die.

Die Cut Mylar Bags Across the USA

We cut and ship shaped mylar pouches free to brands nationwide. An Austin snack brand may want a playful outline, while a Denver cannabis brand may pair a branded shape with a child-resistant zipper. Apexio Packaging serves California, Texas, Colorado, Florida and New York, plus Chicago, Miami and Seattle, with free nationwide shipping.

Wholesale Die Cut Mylar Bags: Zero MOQ and Free Shipping

There is no minimum order, and wholesale pricing improves as volume grows. Order one shaped sample to prove the die, then scale to a larger run for lower per-unit pricing – never a forced minimum. Standard production runs about 5-7 business days after proof approval, with a RUSH lane. Explore related structures on our mylar bags hub. Order now with zero MOQ and free US shipping – get your free quote today.

Our Quality Review Before Production

We review every die cut mylar bag for cut accuracy, seal, barrier and print before it ships. We check the cut line against your die, heat-seal strength around the shape, film gauge and print registration, and confirm the pouch survives filling and shipping. A clean, accurate shape is what makes the branding land, so we hold tight tolerances on every run.

Order Custom Die Cut Mylar Bags Today

Give your product a shape shoppers remember. Start with zero risk: no minimums, free design, a free 3D mockup and free US shipping. Send us your outline and fill weight, and we turn it into a high-barrier die cut mylar pouch – email sales@apexiopackaging.com or call +1 (855) 466-6990.