1 Piece Tyvek Wallet

Tyvek® is an extremely light and tough material. Tyvek® is a material created by Dupont and is used in many application today, including envelopes, banners, and house weather screening.

This instructable is for a 1 piece, no tape, bi-fold wallet. The wallet will have 1 money slot and 2 credit card slots.

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Step 1: Get the Envelope

I found this step the hardest. The USPS, Fedx, and DHL use Tyvek envelopes. I know the USPS and Fedx give away the envelopes for free. I asked nicely at my local USPS and they gave me a bunch of them.

PVC marxman says: May 1, 2007. 7:09 PM

you can order them online from the usps site by the 50 for free

IAmArt says: Feb 17, 2011. 6:48 PM

FYI - There is a legal disclaimer on USPS pouches indicating that misuse of their pouches may be a federal violation and that they belong to the USPS.

Seekan D'Stroy says: Mar 7, 2011. 5:34 PM

True, but they can't and wont know if the wallet is in your pocket...

jbrams says: Dec 17, 2008. 10:26 PM

You diagram provides a good template, though I did find that I had to make several adjustments to make the wallet fit my preference:
(1) I used a 12x15" envelope (priority mail, same as your's I believe)
(2) I used both sides and kept them connected ... that is, the edges parallel to the text were not cut, which basically doubled the tyvek paper for a, hopefully, stronger wallet.
(3) The measurements you included resulted in a somewhat taller than desired wallet ... I wanted mine to be nearly the exact height of a dollar bill, maybe just a bit shorter even ... that makes the credit cards fit more snugly and prevents them from falling out while still allowing many cards (including a dozen business cards with room for twice as many.

To get the shorter height (closer to the height of a dollar bill along it's short sides), and because I used a piece that was actually 12" tall (your diagram calls for (3 x 3.5) + (2 x .125) = 10.75"), I had to make some of the folds a bit longer, particularly, the .5" fold at the bottom became a 1.25", and I had to add a fold at the top that is ~.75" and folded into the dollar bill pocket. This also frames the "priority mail" text and blue stripe nicely.

Also, taking an idea from the "Super Thin Tyvek Card Sleeve Wallet! by marksbrenSuper Thin Tyvek Card Sleeve Wallet! by marksbren" I put a rounded cut into the credit card pockets and a thumb slit on the interior to allow me to push the cards out with one hand.

I'll add a couple photos later, this was a very helpful design!

arden13 says: Jun 14, 2007. 10:46 PM

how do you keep the cards from sliding out? TyVek is too slick, and my cards fall out, what could I put in to help provide some friction?

VanDelay says: Feb 9, 2007. 5:53 PM

FANTASTIC!! I made one with a FedEx envelope and made some measurment changes, the card slots seemed too big with your measurments but otherwise very nice.

mikesty says: Dec 28, 2006. 2:45 AM

I love the 2nd pic with the caption around your brother's feeble attempt to tear the Tyvek envelope. I guess you'll just have to tear him a new one, no?