Custom Non Woven D Cut Bags give businesses a simple way to package products and promote their brand at the same time. The bags feature built-in D-shaped handles that make them easy for customers to carry.

Their lightweight design makes them useful for shopping, events, trade shows, promotions, and everyday retail use. You can add your logo, brand colors, product information, or custom artwork to create bags that customers can use again and again.

At The Pioneer Packaging, we make custom bags in different sizes, colors, and styles to match your products and brand.

What Are Custom Non Woven D Cut Bags?

Non woven D cut bags are reusable carry bags made from non-woven polypropylene fabric. The handle is not a separate strap sewn onto the bag. It is cut directly out of the top of the bag itself, die-cut into a D shape. The customer puts their fingers through the D-shaped opening and picks the bag up.

The “D” refers to the shape of the cutout, a rounded rectangular opening at the top of the bag that forms a built-in carrying handle.

D cut bags feature a die-cut handle directly on the bag, making them lightweight and easy to carry. They are widely used in retail stores, exhibitions, and promotional events.

Non woven die cut bags do three things at the same time.

They carry things. The die-cut handle holds comfortably in the hand for light to medium loads of groceries, clothing, gifts, event swag, and retail purchases.

They carry your brand. Both sides of the bag are large, flat, printable surfaces. Your logo and brand colors go directly on the bag, visible to everyone who sees the customer carrying it.

They replace single-use plastic. A non woven D cut bag is reused dozens of times before it wears out. Every reuse is one less plastic bag in a landfill and one more brand impression for your business.

GSM Guide: How to Choose the Right Fabric Weight

GSM stands for grams per square meter. It tells you how thick and strong the non-woven fabric is. Higher GSM means stronger fabric. Lower GSM means lighter fabric and lower cost per bag.

Fabric weight is available in 60-100 GSM, giving you control over durability vs. economy. Lighter weights (60–80 GSM) are budget-friendly, while heavier options (90-100 GSM) add strength and longevity.

Here is how to choose the right GSM for your specific use.

60 GSM – Light Duty

Feel: Very light – almost like thick tissue paper

What it carries: Up to 3-4 kg, like leaflets, light clothing, event programs, single small products

Best for: Mass giveaway events, trade show promotions, single-use gifting where cost per bag matters more than longevity

Print quality: Good – full-color print applies cleanly

Notes: Below 60 GSM indicates poor durability. 60 GSM is the minimum practical weight for a usable non woven D cut bag.

70–80 GSM – Standard (Most Popular)

Feel: Light but structured – a real bag, not a flimsy one

What it carries: Up to 5-7 kg, like groceries, clothing, medium retail purchases

Best for: Retail shopping bags, grocery bags, boutique carry bags, everyday promotional bags

Print quality: Excellent – the most common GSM range for branded non woven die cut bags

Notes: Minimum 80 GSM for D-cut bags for best durability and customer satisfaction in regular retail and grocery use

90-100 GSM – Heavy Duty

Feel: Substantially heavier – noticeably stronger in hand

What it carries: Up to 8–10 kg – full grocery loads, heavy retail purchases, books, multipacks

Best for: Supermarkets, grocery chains, bookstores, any retail environment where customers load bags with heavy items

Print quality: Excellent – heavier fabric gives a richer print surface

Notes: The right choice if your customers regularly fill bags with heavy items

100-120 GSM – Premium Heavy Duty

Feel: Very substantial – almost textile-like

What it carries: 10-15 kg and above – the maximum practical weight for a D-cut style

Best for: Industrial supply bags, hardware store bags, bulk packaging, any application where the bag carries heavy or awkward loads repeatedly

Print quality: Premium – the thick fabric surface gives maximum print vibrancy

Notes: For loads above 8 kg, choose 100+ GSM with reinforced handles.

Printing Options for Custom Non Woven Die Cut Bags

Your logo on a non woven bag is not a sticker or a label. It is printed directly into the fabric and it needs to stay sharp and vibrant through dozens or hundreds of uses.

Screen Printing

The most common printing method for non woven D cut bags. Ink is pushed through a mesh screen onto the fabric surface one color at a time.

Best for: 1 to 4 color logos, simple designs, high-volume orders

Colors: Pantone-matched spot colors – accurate and consistent across large runs

Durability: Very high – the ink bonds to the fabric fibers

Cost: Most cost-effective for simple designs at volume

Heat Transfer Printing

A full-color design is printed onto a transfer film and heat-pressed onto the bag surface.

Best for: Full-color photographic designs, complex gradients, multi-color artwork

Colors: Full CMYK – any color, any gradient

Durability: Good – transfer bond holds well through repeated use

Cost: Higher per unit than screen printing for simple designs

BOPP Lamination + Offset Print

A BOPP (biaxially oriented polypropylene) film is heat-laminated to the bag surface and printed using offset lithography before lamination.

Best for: Premium non woven die cut bags where maximum color vibrancy and a glossy or matte surface finish are required

Colors: Full CMYK photographic quality – the most vibrant print option available for non woven bags

Durability: Excellent – the laminate protects the print from scuffing and moisture

Cost: Highest per unit – justified for premium retail, corporate gifting, and any bag where the print quality IS the brand statement

Standard Sizes for Custom Non Woven D Cut Bags

All sizes are fully custom, but here are the most common formats for reference.

Small (Boutique and Single-Item)

Typical dimensions: 8″×10″ to 10″×12″

D-cut handle size: Approximately 5″×1.75″

Best for: Single garment, small gift items, cosmetics, jewelry retail

Gusset: Usually no gusset for single small items

Medium (Standard Retail)

Typical dimensions: 12″×14″ to 14″×16″

D-cut handle size: Approximately 6″×2″

Best for: Multi-item retail purchases, clothing, books, medium groceries

Gusset: Optional 2″–3″ bottom gusset for multiple items

Large (Grocery and Supermarket)

Typical dimensions: 14″×18″ to 16″×20″

D-cut handle size: Approximately 7″×2.5″

Best for: Full grocery loads, supermarket carry bags, bulk retail

Gusset: Standard 3″–4″ bottom gusset – customers fill these with heavy items

Extra Large (Trade Show and Event)

Typical dimensions: 16″×18″ to 18″×20″

D-cut handle size: Approximately 8″×2.5″

Best for: Trade show swag bags, conference kit bags, large promotional giveaways

Gusset: Optional – depends on load requirements

Custom Dimensions

Any size outside the above – built to your exact product, display, or event requirement.

Who Uses Custom Non Woven D Cut Bags

Retail Stores and Boutiques

D cut bags are widely used in retail stores; they are lightweight, easy to carry, and give the brand a large print surface for logo visibility. A boutique handing a customer a custom non woven D cut bag with their logo turns every customer into a walking advertisement the moment they step onto the street.

Grocery Stores and Supermarkets

Grocery chains across the USA are replacing single-use plastic bags with custom non woven die cut bags, branded with the store name and available for purchase or free with qualifying purchases. Customers reuse them every week, and the store’s brand travels with them every time.

Trade Shows and Corporate Events

D cut bags are widely used in exhibitions and promotional events. A trade show bag printed with your company logo holds brochures, product samples, and giveaway items and gets carried home by every attendee, keeping your brand visible long after the event ends.

Pharmacies and Healthcare Brands

Non woven D cut bags work perfectly for pharmacy carry bags – lightweight, clean-looking, easily printed with the pharmacy logo and contact information. Customers carry their prescriptions and health products home in a bag that doubles as a quiet brand advertisement in the neighborhood.

Food Brands and Bakeries

Bakeries and specialty food brands use non woven die cut bags for carry-out purchases – branded with the shop name and food photography. The reusable bag signals sustainability and quality simultaneously.

Schools and Non-Profits

Schools and non-profit organizations use custom non woven D cut bags for fundraising, events, and branded giveaways – printing the organization name, event, or cause messaging on both sides of the bag.

Corporate Gifting

Companies fill custom non woven D cut bags with branded merchandise, product samples, and event materials, distributing them to employees, clients, and conference attendees as a cost-effective branded gift with real utility.

Sustainability

The D-cut non woven bag is quickly replacing plastic bags because it is great for repeated use – sustainable and eco-friendly for the environment.

Reusability: A non woven D cut bag at 80 GSM or above withstands hundreds of uses before it wears out – replacing dozens of single-use plastic bags over its lifetime.

Recyclable polypropylene: The non-woven PP fabric is recyclable through polypropylene recycling programs. Unlike multi-material plastic bags, PP non woven bags are a single-material product – easier to process in recycling systems.

No plastic bag replacement cost: Many US cities and states have imposed bans or fees on single-use plastic bags. Custom non woven D cut bags comply with those regulations by design – reusable, durable, and plastic-fee exempt.

Eco-friendly print options: If branding matters, confirm the supplier uses water-based or soy-based inks. Solvent-based inks may emit VOCs and are less eco-friendly. We use water-based inks on all non woven bag printing – no harmful VOC output, full recyclability compatibility.

20% post-consumer recycled content: Premium non woven die cut bags are available with 20% post-industrial recycled content, reducing virgin polypropylene use without compromising bag performance.

Full Customization Options

Bag style: D cut (this product), with or without bottom gusset, with or without side gussets

GSM (fabric weight): 60 GSM (light promo), 70-80 GSM (standard retail), 90-100 GSM (heavy duty), 100-120 GSM (premium heavy duty)

Handle shape: Standard D cut – rounded corners (40% lower tear risk than sharp corners)

Seam method: Heat seal (light to medium loads, cost-effective), ultrasonic welding (heavy loads, maximum durability)

Colors: Any base fabric color – white, natural, red, blue, green, black, custom color

Print method: Screen printing (1-4 colors, high volume), heat transfer (full CMYK, any design), BOPP lamination + offset (premium, maximum vibrancy)

Logo placement: Front panel, back panel, or both – full printable surface on each side

Sizes Small (boutique), medium (retail), large (grocery), extra large (trade show), or fully custom dimensions

Gusset options: No gusset (flat), bottom gusset (2″-4″), side gussets, or both

Sustainability: Water-based inks, 20% post-consumer recycled content option, recyclable PP material

Turnaround: 10–12 business days from art approval

Shipping: Free across all USA

Why Choose The Pioneer Packaging?

At The Pioneer Packaging, we make reusable non woven bags that combine practical design with strong branding. We help businesses create packaging that customers can use again and again.

What We Offer

• No Minimum Order Quantity
• Free Shipping Across the USA
• Free Design Support
• Wholesale Pricing
• Fast Turnaround Times
• Custom Sizes
• Custom Printing
• Reusable Packaging
• Durable Construction
• Dedicated Packaging Support

Whether you need bags for your retail store, promotional event, or product launch, we can create custom D cut bags that fit your brand and business needs.

Frequently Asked Questions

What are custom non woven D cut bags?

Custom non woven D cut bags are reusable carry bags made from non-woven polypropylene fabric where the handle is a D-shaped opening die-cut directly into the top of the bag rather than a separate sewn strap. Your logo and brand colors are printed directly on both sides of the bag. They replace single-use plastic bags and give your brand a moving advertisement every time a customer carries one in public. They are also called non woven die cut bags or D cut carry bags.

What GSM should I choose for my non woven D cut bags?

For light promotional giveaways and single-use gifting, 60 to 70 GSM. For standard retail carry bags and grocery bags used regularly, 70 to 80 GSM. For heavy grocery loads and everyday reuse, 90 to 100 GSM. For industrial and bulk carry applications,100 to 120 GSM. The GSM you choose determines how many kilograms the bag carries safely and how many times it can be reused before wearing out.

What is the difference between D cut and W cut non woven bags?

A D cut bag has a rounded D-shaped opening cut directly into the top of the bag; the customer puts their fingers through the opening for a hand carry. A W cut bag has a wider, vest-shaped opening that allows the bag to be carried by hand or over the shoulder more comfortably for heavier loads. D-cut bags are the most cost-effective style and work perfectly for light to medium loads. W-cut bags are slightly more expensive and better suited for grocery and supermarket use where customers carry heavier items.

Why do rounded corners on the D-cut handle matter?

Rounded corners reduce tear risk at the handle opening by approximately 40% compared to sharp-corner die-cut designs. When a customer picks up a bag, all the carrying force concentrates at the two corners of the handle cutout. A sharp corner creates a stress point where the fabric tears under repeated use or a heavy load. A rounded corner spreads that stress across a curve; the handle lasts longer and feels more secure during use. Every custom non woven die cut bag we produce uses precision-rounded D-cut handles.

Do I need a gusset on my non woven D cut bag?

Add a gusset if your customers will put multiple items in the bag or if the bag needs to stand upright when full. Grocery stores, supermarkets, multi-item retail, and food carry all benefit from a bottom gusset. Skip the gusset if your bag carries a single flat item: one garment, one box, one document, or if you are using the bag as a flat event giveaway where fold-flat storage and low cost per unit are the priority.

How long does production take and is shipping free?

Standard production runs 10-12 business days from final art approval, not from the date of initial order. Bag engineering, GSM selection, gusset confirmation, D-cut handle sizing, 3D mockup approval, and artwork sign-off all happen before the production clock starts. Free shipping is included on every order across the entire USA. No freight surcharge, no handling fee, no minimum order value required.