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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.

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.

Step 2: Template/Measurements

These picture is of the measurements, also attached is the E-machine shop file.

Step 3: Photo Step by Step

Descriptions Are Written on the Photos

Step 4: Video



Step 5: Well That Is It.

Just fold and you are done. You don't need to make it out of tyvek, card-stock and paper are other options.
you can order them online from the usps site by the 50 for free
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.
True, but they can't and wont know if the wallet is in your pocket...
You diagram provides a good template, though I did find that I had to make several adjustments to make the wallet fit my preference:<br/>(1) I used a 12x15&quot; envelope (priority mail, same as your's I believe)<br/>(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.<br/>(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.<br/><br/>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&quot; tall (your diagram calls for (3 x 3.5) + (2 x .125) = 10.75&quot;), I had to make some of the folds a bit longer, particularly, the .5&quot; fold at the bottom became a 1.25&quot;, and I had to add a fold at the top that is ~.75&quot; and folded into the dollar bill pocket. This also frames the &quot;priority mail&quot; text and blue stripe nicely.<br/><br/>Also, taking an idea from the &quot;<a rel="nofollow" href="https://www.instructables.com/id/Super-Thin-Tyvek-Card-Sleeve-Wallet!/">Super Thin Tyvek Card Sleeve Wallet! by marksbren</a>Super Thin Tyvek Card Sleeve Wallet! by marksbren&quot; 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.<br/><br/>I'll add a couple photos later, this was a very helpful design!<br/>
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?
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.
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?
This is really cool-- but could you possibly add a photo step-by-step? It'd be a bit easier to follow.
Alright, done.
Cool. I currently have a duct tape wallet but if i get around to getting a Tyvek envelope i think i'll switch.

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