What does "Return label not sent" mean on an existing Shopify return?

When does Shopify show "Return label not sent"?

You may see Return label not sent when you try to add a return label to an existing return. Per Shopify's return-label guide, it happens when you "initially created a return without a shipping label and later tried to add one."

If the label exists but never reached the customer, resend it instead: in the order's Return label section, click View details, then Email customer, Copy link or Print label.

How do you add a return label to an existing Shopify return?

Shopify's workaround puts the label on a new return instead:

1. Edit the order and use + Add custom item to add a free custom item named "Return shipping label".
2. Fulfill the free item.
3. Create a new return for that custom item.
4. While creating it, immediately upload or create the return label (see which carriers Shopify can create it with).

If step 1 is blocked, see why Shopify blocked that edit. You can create a return only for fulfilled items that haven't been refunded.

Creating the label in Shopify at step 4 works only if your primary location (Shopify's return-label guide says fulfillment location) and the customer's shipping address are both in the US; otherwise upload one as a PDF, PNG, JPEG or URL. For the label screen, see how to create a return label.

What does the workaround change on your Shopify order?

Per Shopify's general editing rules, a custom item with a 0 price doesn't change the order total. An edit made after the day the order was placed shows in reports as a separate order, and app data might be incorrect, most likely in fulfillment apps.

Shopify's four steps don't include any action on the first return. If you decide to cancel it, Shopify allows that only if it isn't refunded or restocked, is open and not Marked as returned, has no return label, and its fulfillment isn't canceled. It can't be reopened afterwards.