A1 DVD / A5 Size Cardboard Envelope Mailer - Expandable Envelopes

Indestructible DVD Packaging - Fits 100% of DVDs, Blu Rays & video games

The Lil A1 DVD / A5 envelope is our best selling cardboard DVD mailer, purpose built to fit 100% of DVDs, Blu-rays and video games. As a CD/DVD mailer it's designed to accommodate Royal Mail's large letter tariff flat packed, or the small parcel tariff when expanded, so you're never overpaying to post a disc. For the full picture on why this matters, see our large letter packaging guide.

With its robust, natural finish, your customers open attractive packaging to receive their DVDs (standard case size 136 x 192 x 13mm) in the condition you posted them in. Manufactured using corrugated cardboard with special folds that buffer the edges, minimising the risk of splitting or shattering the cases inside. Our leading peel'n'seal / tear strip system makes sealing and opening effortless. Read more on safely packaging and mailing CDs and DVDs in our knowledgebase.

The corner stiffness of the A1 envelope cuts damage in transit, online retailers report nearly 70% fewer returns and 25% faster packing versus bubble mailers.

All Lil envelopes are made from 100% recycled material and are 100% recyclable, a plastic free alternative to the bubble mailer. This range was developed alongside one of the internet's largest retailers, so you might recognise it. Explore the wider corrugated envelope range for other flat pack sizes.

Lil Packaging is Europe's largest independent producer of CD/DVD mailers and cardboard envelope mailers, trusted by 10,000+ brands.

This brilliant, tough little envelope is our best selling item for a reason. If you are looking for sturdy and cost effective packaging for mailing DVDs, blu-Rays or video games, consider nothing else (don't use cheap DVD envelopes that fall apart, leave your items damaged and your customers dissatisfied).

Go on...burst that bubble!

Why choose our A1 DVD / A5 size cardboard mailer

• Fits everything: one size accommodates DVD, Blu-ray and video game cases, no need to stock multiple mailer sizes
• Postage smart: flat packed within Royal Mail's large letter tariff, expanded within small parcel, so you always pick the cheapest rate for the job
• Tamper evident: peel and seal closure forms a permanent bond, so damage or tampering is obvious before the parcel is opened
• Built to protect: corrugated cardboard with reinforced folds absorbs impact at the corners, where disc cases are most vulnerable
• Genuinely sustainable: FSC certified, Plastic Free and Zero Carbon as standard
• Proven at scale: developed alongside one of the internet's largest retailers and used by 10,000+ brands

Product Specification

• Size: 235 x 176mm flat, expands to 195 x 140 x 40mm
• Material: E flute corrugated cardboard, approx 1.5mm thick
• Closure: Tamper evident peel and seal (permanent bond)
• Postal fit: Designed to accommodate Royal Mail's large letter tariff flat packed, or the small parcel tariff when expanded (Large Letter tariff)
• Certifications: FSC certified, Plastic Free, Zero Carbon

What size DVD case does the A1 envelope fit?
The A1 is sized to fit standard DVD cases (136 x 192 x 13mm) as well as Blu-ray and video game cases. Flat packed it measures 235 x 176mm, and it expands to 195 x 140 x 40mm to accommodate box sets or slightly deeper cases without needing a different mailer size.

Is this a CD/DVD mailer or just for DVDs?
Both. The A1 is built as a genuine CD/DVD mailer, it accommodates CDs, DVDs, Blu-rays and video games within the same flat pack size, so you can standardise on one mailer across your whole media range rather than stocking separate sizes.

Does the A1 fit Royal Mail's large letter tariff?
Yes, flat packed the A1 sits comfortably within Royal Mail Large Letter Maximisers - Lil Packaging, the cheapest posting option available. If you need the expanded box form for a bulkier item, it moves into the small parcel tariff instead, still cost effective versus a rigid box.

What's the difference between the A1 and other cardboard envelope sizes?
The A1 is our smallest wide opening mailer, designed specifically around single disc case dimensions. If you need to post larger flat items like books, box sets or multiple discs together, the full Cardboard Envelopes Wide Opening A Range - Lil Packaging covers sizes up to A5 for bigger or bulkier contents.

Is the A1 mailer plastic free and recyclable?
Yes, the A1 is made from 100% recycled corrugated cardboard and is fully recyclable. It's certified Plastic Free Packaging - Lil Packaging and forms part of our Zero Carbon Packaging - Lil Packaging packaging range, so it's a genuine sustainable alternative to bubble mailers.

Does the A1 envelope protect against damage in transit?
Yes, the corrugated construction includes reinforced folds at the corners, the point where disc cases are most likely to crack or shatter in transit. Combined with the tamper evident peel and seal closure, retailers using the A1 report meaningfully fewer returns and faster packing times than with bubble mailers.

How is the A1 sealed and opened?
The A1 uses our peel and seal / tear strip closure system, a permanent adhesive bond for tamper evident security, paired with a tear strip for quick, clean opening on the customer's end, no scissors or tape needed.