Sheet with cushioning inserts

A cushioned mailer comprising:

• a first layer defining a plurality of first sockets;
• a second layer defining a plurality of second sockets, each of the first sockets aligned with a corresponding one of the second sockets to define a void therebetween;
• and
• a cushioning insert received within each of the voids;
• wherein the first layer is coupled to the second layer to define a cushioning sheet, the cushioning sheet defining an inner cavity configured to receive contents, the inner cavity at least partially surrounded by the second layer, the first layer facing away from the inner cavity.

A method of forming a cushioning sheet comprising:

• forming a plurality of first sockets in a first layer;
• forming a plurality of second sockets in a second layer, each of the second sockets corresponding to a one of the first sockets;
• positioning a cushioning insert within a void defined between each corresponding pair of the first and second sockets;
• and
• coupling the first layer to the second layer.