Video Mailer Dimensions: Sizes, Formats & Custom Options
Video mailer dimensions depend on the screen size, mailing format, battery capacity, and internal structure. This guide covers common video mailer sizes, thickness considerations, and custom options for direct mail campaigns.
Unlike traditional printed mailers, there is no single standard video mailer size. The final dimensions depend on several factors, including:
- Screen size and orientation
- Printed message area
- Button layout
- Battery and electronic components
- Protective structure
- Mailing requirements
CheerTrend provides commonly used video mailer formats from compact direct mail designs to larger premium presentation formats. Custom dimensions are also available for specific projects.
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Common Video Mailer Sizes by Screen Size
Based on CheerTrend’s production experience, the following table shows commonly requested video mailer formats from our customer projects. These formats can be customized according to specific project requirements.
| Screen Size | Typical Video Mailer Format | Viewing & Design Considerations | Common Applications |
|---|---|---|---|
| 4.3″ | Compact video mailer formats | Small and lightweight design, ideal when mailing cost and portability are priorities | Direct mail campaigns, invitations, event promotions, product announcements |
| 5″ | Standard promotional video mailer size | A good balance between screen visibility, production cost, and mailing convenience | Real estate marketing, healthcare introductions, product marketing, customer outreach |
| 7″ | Premium video mailer format | Larger viewing area with stronger visual impact while maintaining a practical mailing size | High-value marketing campaigns, corporate presentations, sales proposals, luxury products |
| 10.1″ | Large custom video mailer formats | Requires more space for the LCD module, battery, and structure; usually designed for special projects | Luxury product launches, VIP presentations, events, premium brand campaigns |
Manufacturer Insight: The 4.3″ and 5″ screen formats typically share a similar overall footprint, with the size difference mainly reflected in bezel width rather than the outer dimensions. This allows for a consistent mailing format across both screen sizes.
Choosing the right screen size depends on your marketing goals, viewing distance, and budget. Learn more about video mailer sizes and screen options.
How Screen Size Affects Video Mailer Dimensions
The screen size is one of the main factors affecting the final product dimensions. A larger screen provides a stronger visual impact but requires more space for the LCD display area, electronic components, battery capacity, speaker placement, and printed content area.
Compact Video Mailers (4.3″–5″)
Smaller video mailers are suitable when the goal is easy distribution, lower shipping cost, large quantity campaigns, and direct customer outreach. Common applications include event invitations, promotional campaigns, sales follow-up materials, and small product introductions.
These formats are commonly selected when shipping cost and portability are important. They provide enough screen space for product introductions, invitations, and short promotional videos.
Standard Video Mailers (7″)
A 7-inch video mailer provides a larger viewing area while maintaining a practical format for mailing and distribution. It is commonly selected for real estate presentations, healthcare information, corporate marketing, and product demonstrations. The larger screen allows companies to present more detailed video content with stronger visual impact.
The 7-inch video mailer is one of the most popular choices because it provides a larger viewing area while keeping the overall format practical for shipping.
See our guide to 7-inch video mailers for more details.
Large Format Video Mailers (10.1″)
Large screen video mailers are designed for projects where presentation quality is the priority. Typical applications include luxury product launches, high-end corporate presentations, premium client proposals, and brand experiences. The larger format provides more space for both video display and printed messaging.
Sample orders typically ship within 2 business days.
Video Mailer Structure and Size Considerations
The finished dimensions of a video mailer depend not only on the screen size but also on the internal structure. A typical video mailer includes a printed outer cover, LCD screen area, control buttons, speaker opening, battery compartment, and electronic components.
Different designs may require additional space depending on the number of buttons, battery capacity, speaker configuration, video playback requirements, and packaging style. For this reason, the same screen size can have different final dimensions depending on the product design.
Key factors affecting final dimensions:
- LCD screen size
- Battery capacity
- PCB and speaker placement
- Printed cover thickness
- Mailing requirements
The final dimensions are also affected by battery capacity, memory requirements, and electronic components.
Can Video Mailers Be Mailed Directly?
Yes. Video mailers are specifically designed for direct mail campaigns.
However, the mailing method depends on the final product specifications, including overall dimensions, thickness, weight, protective packaging, and destination and shipping requirements.
Before production, companies should consider both the marketing purpose and the mailing process to select the most suitable format. For large direct mail campaigns, optimizing the size and structure can help balance customer experience, protection during shipping, and mailing cost.
Depending on the final thickness and destination requirements, video mailers can be shipped through direct mail campaigns, courier services, or custom packaging solutions.
Video Mailer Dimensions vs Video Brochure Dimensions
Although video mailers and video brochures use similar LCD video technology, they serve different purposes. Learn more about the difference between video mailers and video brochures.
| Video Mailer | Video Brochure | |
|---|---|---|
| Main purpose | Sending directly to recipients | Presenting during meetings or events |
| Design priority | Mailing convenience | Presentation experience |
| Structure | Designed for direct distribution | Designed as a marketing brochure |
| Size consideration | Mailing size and protection | Viewing experience and printed layout |
How to Choose the Right Video Mailer Size
1. Marketing Purpose — Is this for mass distribution or premium clients? Does the recipient need a quick introduction or a detailed presentation?
2. Video Content Length — Short promotional videos may work well with compact formats. Longer presentations, product demonstrations, or educational content may benefit from larger screens.
3. Mailing Requirements — If the product will be shipped to hundreds or thousands of recipients, the final dimensions and weight should be considered early in the design process.
4. Brand Experience — A larger format creates more visual impact, while a compact format can improve convenience and distribution efficiency.
For most marketing campaigns, 5-inch and 7-inch video mailers provide the best balance between viewing experience, production cost, and shipping convenience.
Cost is another important factor when selecting a video mailer size. View our video mailer cost guide for pricing considerations.
Frequently Asked Questions About Video Mailer Dimensions
A typical video mailer size depends on the screen size and mailing requirements. Common formats include DL, A5, and custom sizes designed around 4.3-inch, 5-inch, or 7-inch LCD screens.
For most direct mail campaigns, customers choose compact sizes that are easy to ship while still providing enough space for printed messaging.
Common video mailer formats include:
- DL size: compact direct mail format
- A5 size: larger format with more printing space
- Custom sizes: designed for specific products, packaging, or campaigns
The final dimensions depend on the LCD size, battery, electronics, and printed content requirements.
The most common screen sizes are:
- 4.3-inch LCD: compact and cost-effective
- 5-inch LCD: good balance between size and viewing experience
- 7-inch LCD: premium option for larger presentations
The screen size should be selected based on mailing purpose, viewing distance, and budget.
Yes. Video mailers can be customized according to the required mailing format, screen size, printed area, battery capacity, and internal structure.
Custom dimensions are commonly used for real estate campaigns, product launches, healthcare marketing, and corporate promotions.
Not always.
A video mailer is designed for direct distribution and shipping, so the priority is compact size and protection.
A video brochure focuses more on presentation experience, printed layout, and larger viewing areas.
Thickness depends on the screen size, battery, and structure.
Most video mailers are designed to remain slim enough for mailing, while still providing enough space for the LCD module and electronics.
Some compact video mailers can be designed for envelope mailing, depending on the final thickness, screen size, and mailing requirements.
The best size depends on the campaign goal. 5-inch and 7-inch video mailers are commonly selected because they provide a good balance between screen visibility, cost, and shipping convenience.
Some compact video mailers can fit into standard mailing envelopes, depending on the screen size, thickness, and internal components. Smaller formats such as 4.3-inch and 5-inch video mailers are often designed for direct mail campaigns where portability and shipping convenience are important.
For larger formats, such as 7-inch or 10.1-inch video mailers, custom packaging or protective mailing solutions are usually recommended to accommodate the larger screen, battery, and electronic components.
Not sure which size fits your project?
Every video mailer project can be customized based on your requirements. CheerTrend supports different screen sizes, portrait or landscape orientation, custom printed covers, different button configurations, customized internal layouts, and preloaded video content.
Whether you need a compact direct mail campaign or a premium branded presentation piece, we can help design a suitable video mailer format.