In 2005 I had the idea to make the first folded Tyvek Wallet.
My inspiration came from seeing the Duct-tape wallets that many DIY'ers were making. The only problem I found was that the material itself was bulky and didn’t fold very well. For a long time I kept sheets of Tyvek hanging in my studio for inspiration and then I had a eureka moment. After searching on google I was amazed that no results turned up for a Tyvek Wallet.
I wanted the Tyvek wallet to be made without stitches since this is always were most wallets fail. This would also allow the Tyvek material to remain strong (without putting tiny stitching holes in it). It was a real struggle to design and realize this product. You can read more about the first Tyvek Wallet design on my blog.
Today the idea of a Tyvek wallet is becoming very common so I thought it was important to let other DIY'ers know about the first Tyvek Wallet design. My latest Tyvek wallets, I now call them "Mighty Wallets" are online here. I also make tons of videos of the Mighty Wallets on YouTube.
Years later I was contacted by a producer at the Martha Stewart show who wanted me to show them how to make a tyvek wallet using accessible materials. Most people can find Tyvek envelopes so I used that as the basis for my design. The final design uses the actual self-sealing closure of the envelope itself as the binding mechanism that holds the wallet together.
Here is video demonstration of these same instructions
Step 1: Orientation / Folding
You will need
- Standard size self-seal Tyvek envelope (preferably 9 x 12 inches)
- Double stick tape
- X-acto knife
- Cardboard (slightly smaller than envelope, to use as cutting mat)
Note: To simplify the directions I need to establish few terms regarding the orientation of the envelope. First the (Top)of the envelope is the open end with the self-sealing flap, the bottom is the closed end. Vertical refers to the length of the envelope (12in), Horizontal to the width (9in).
Important: Keeping this orientation with help when we refer to vertical and horizontal folds and creases.
Place envelope address side down, fold in half along the length (12 in side), bringing the bottom edge up to self-seal crease on the flap. Make a sharp crease.
Step 2: Fold Twice
Step 3: Fold Three Times
Step 4: First Cuts
Step 5: Open the Flaps
Step 6: Cut Circle and "I" Shape
Next, cut out the capital letter i - Remove the cardboard and place envelope on top of it. Cut the vertical fold beneath the circle, this time cutting through both sides of the envelope. Then make a horizontal cut along the middle and bottom crease 1 in wide using the vertical crease as the center of the 1 in cuts. Again, cut through both sides.
Step 7: Cut Open the Bottom
If you want to decorate the wallet with graphics you can use the area illustrated here to transfer graphics, use stamps, stencils, markers etc to customize the wallet design. Tyvek is not reliable to print on using ink jet printers since it could clog the printer head. Do so AT YOUR OWN RISK!
You can also use markers, ink stamps, spray paint, tape and other methods to decorate your wallet.
Step 8: Apply Tape
Apply double stick tape to the tabs on the side facing you. Now fold the tabs portion up towards the self-seal flap, sealing the double stick tape by pressing down hard to secure the tabs. This creates two credit card holders.
Step 9: Fold Flaps in and Tape
Step 10: Seal and Close
You might want to try this a couple times before removing the backing. Work from the center to the edges and be careful the self-stick tape can be tricky to handle.
Now you have a lightweight, thin, strong, water-resistant wallet that is made from 25% recycled materials and is 100% recyclable (grade 2).