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Selecting the Right CD Sleeve for You Next Project

CD sleeves are one of the least expensive and most flexible packaging options. But which one is the right choice for your next project? Here's a primer on the different options to help you.

First, let's look at the materials commonly used in CD sleeves. When selecting a material for your disc sleeve, ask yourself how will your customer use the CD or DVD? If the disc is something they will use regularly your packaging decision will be different than if the disc is a one-time use marketing piece.


Tyvek is very strong and doesn't rip making it perfect for heavy duty conditions. It is also moisture resistant, which means your CD sleeve can withstand the elements or a spilled cup of coffee. Tyvek CD / DVD sleeves are silky smooth and have a distinctive look and feel. Tyvek is made from 100% high density polyethylene, essentially continuous fibers, so you get a CD sleeve that's incredibly durable, lint free and helps prevent scratched discs.


Paper is your basic, least expensive option. Select a colored sleeve to match your disc art or logo. Slightly more expensive than white envelopes, but still incredibly inexpensive (as low as .061/piece), colored disc sleeves can help make your disc get noticed.


Paperboard (or cardboard) is more durable than paper, but not as indestructible as Tyvek. Many Polyline customers use this to send discs in the mail because it is inexpensive and lightweight.


Vinyl is the "old school" standard. It looks thick and durable, which gives both the disc sleeve and your media a higher perceived value. Vinyl can react chemically with the disc, however, making it a poor choice for archiving.


Polypropylene is an overall good performer. Lightweight and stronger than vinyl, polypropylene does not react chemically with disc. It's also clearer and less expensive than vinyl.


Polyline carries the EcoEndure sleeve which is made from a polylatic-acid based polymer (PLA). PLA film is made from plants like sugarcane and corn. That makes it compostable and is entirely environmentally friendly since it starts as a natural product and ends as a natural product with no impact on the environment.

The next big distinguishing feature of disc sleeves is the flap or, in the absence of a flap, the opening.

Vinyl Sleeve with Pouch Flap

Short Flaps

Short flaps are usually about 1" in size and have a lick and stick adhesive strip. Some of our CD envelopes have a peel and seal adhesive which seems to hold closed better. Peel and Seal strips are an excellent choice for adding a CD or DVD to another boxed product, where the disc will be shaken around.

Pouch flaps

The flap covers the entire sleeves and functions as a pouch to hold a standard size CD booklet.

No Flaps

Disc sleeves without flaps are less expensive than their flapped counterparts. They are also a good choice when you have a lot of discs to pack. Ask yourself, how will you pack your disc?

Flush cut – perfectly even opening, designed for autoloaders.

Uneven opening – Easy to open, which makes them an excellent choice for hand loading a lot of discs.

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