Instructables
Here are basic instructions for making a laptop sleeve out of FedEx envelopes. I was looking for a strong and waterproof material to make my own sleeve from and remembered that FedEx and the US Postal Service both use Tyvek (or similar) material for their envelopes. My sleeve fits a MacBook, but the design is easily adaptable for other sized laptops.

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Step 1: Materials

Find yourself 3 or 4 FedEx envelopes. This sleeve takes 3.

Step 2: Padding

Cut your padding material to fit the inside of the envelope. I used felt. Then stuff it into the envelope.

Step 3: Trim

Trim the adhesive flap from the bag.

Step 4: Mark Dimensions

Mark the size of the sleeve. *Note* Leave some extra room on the sides and top (1/4-1/2") for the thickness of the laptop and the seam allowance).

Step 5: Sew Pocket

Pin and sew along your lines and along the opposite side edge (shown right). This leaves an opening for the laptop (bottom).

Step 6: Trim Seems

Trim the seams.

Step 8: Start Flap

Measure and mark the width of the folding flap.

Step 9: Pin Flap

Sew the flap to size and trim the seam. Pin the flap to the inside back of the pocket. You may notice that I mistakenly sewed it to the front on my first attempt (sigh).

Step 10: Attach Flap

Sew the flap to the pocket. I also sewed around the top of the pocket to hold the padding in place.

...yes, I am using red thread on the spool and purple on the bobbin. So what, I liked it.

Step 11: Fold Flap

That's basically it.
Hey, great idea. I'm thinking about combining this and the hoodie sleeve idea. Hoodie as the outer shell, with a layer of padded FedEx envelope as the outer inner lining, bubble wrap as a middle inner lining, and cloth as the inner lining. The only problem's that I'd have to modify the waterproof envelope and sew it in to attach. Is there anyway y'all can think of doing this while keeping this waterproof? Thanks!
Waterproof zipper?
The aper dont destroy or cut in a bag o.o?¡?
Stan1004 years ago
I did something similar with a bag from Staples. It fits netboooks or a smaller iBook perfectly! 

http://www.instructables.com/id/Use-a-Bubble-Mailer-for-a-Netbook-or-Laptop-Sleeve/
Fieldownage4 years ago
I was wondering this out but realized that couldn't you just use a tougher envelope with a layer of bubble wrap inside it.
awesome! im going to try this for my Acer Aspire One, soon as i get some envelopes :P five stars and fav'd :)
toxictort5 years ago
Using the fused plastic instructables, you can create a "skin" for this case. Very trendy, still waterproof and really trendy (like patent leather) and cool. Just a thought :)
amcwood5 years ago
Ever notice the arrow between the E and the x? If you didn't, that's all you will see from now on. They spent so much money for that arrow. Sorry thought I would pass on my torment. Very slick I'm going to do this next chance I get. Thanks for the Idea
puramu5 years ago
Awesome bag! I took some of your cues and made a sleeve. Check it out.

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I think the lazier way would be to buy a macbook air.
wandering6 years ago
Great idea. It would be even more environmentally friendly if you just asked friends who get FedEx envelopes to save a few for ya'. That way, you'd be using something that would have ended up in the trash. Plus, with an address etc on it, it would look more like something not worth stealing.

I checked with Dupont's Tyvek envelope website and while the tyvek is very durable, it's only water resistant. If you want to make it even better, seal the inside with something like AquaSeal Map Seal (water based environmentally safe). Plus if you want a lining and worried about static, make an inner sleeve cut from a used paper grocery bag.

I plan on making one. My laptop will be inside a daypack but thought it would be nice to have a little more protection. Thanks again for the idea.

Jim WanderingTheWorld.com
camp6ell6 years ago
the red and purple thread is genius. great design touch.
stephanie_c6 years ago
i just made this, thanks for the great idea! my kitty loves plastics as well. one note, i was a little confused at first as the instructions didn't spell out that on step 5 you are to sew two bags together, but it all came together perfectly in the end.
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Hay waynestead did u added a strap to it ?
I know how you can make it a messenger bag you can cut the fourth bag in to strips and sew that on! ill try make this bag but ill make it in to a messenger laptop case.
im srry i dont know if i can try make this my parrents might think im up to something bad when im make things like this so ill still try if i can make an instructables
lohroffc6 years ago
When using USPS material, keep in mind "Packaging supplies provided by the United States Postal Service are solely for use in sending Express, Priority, Global, or Global Express Mail via USPS. Misuse may be a violation of federal law."
waynestead (author)  lohroffc6 years ago
Thanks for the reminder. That's why I used FedEx (not usps) and asked, politely if i could have the envelopes.
beccane6 years ago
sorry, color me thick but I can't figure out how this gets made. I'm wondering 1. you just stuff felt into the empty bag? then what? 2. What does he mean by "the pocket"? and how do you turn it inside out? And why doesn't the photo look like anything has been turned inside out? 3. Why do you need 3 or 4 bags when it looks like you need 2 at maximum? 4. Is there padding in the flap? Should there be?
waynestead (author)  beccane6 years ago
1. stuff felt in 2 bags or 3 if you want a padded flap. 2. if you sew the 2 felt-stuffed sides together, you make a pocket or sleeve. If you sew it inside-out, when you reverse it, you won't see the seams. 3. I always keep an extra in case I screw up. 4. yes and that depends - the more padding, the safer the laptop. Thanks everyone for all your comments!
stevenno6 years ago
THIS IS A GREAT IDEA! I am going to try it tonight.

Check out this post (WITH PICS) of a guy that took this idea one step further and added a liner from an old pillow case(?).
majapapaya7 years ago
This design is awesome! I've been on the hunt for a laptop sleeve for awhile but wanted something unique. This is UNIQUE! I had thought about making my own and now I will. I'm thinking about getting clear contact paper and putting a map on the outside. Can't wait! Thanks
billygerald7 years ago
Don't get me wrong...I'm all for helping save the environment...BUT...don't you think the greater impact is the fact that you're buying a $2000 computer that's made in China versus a laptop sleeve that you can buy at Office Depot for $14.99 that was made in China? I'm pretty sure more fossil fuel is consumed in making the laptop than it is in making the laptop sleeve!
Ora billygerald7 years ago
Because, the laptop was already purchased, and saying, "someone just buying an office depot sleeve wont hurt the environment THAT much." Is redundant. If everyone who has a laptop sleeve made it themselves, massive amounts of CO2 would not be in the atmosphere currently, AND I could say the same thing, "just making one sleeve isn't going to save the environment." But all it takes is for one or two people to see this and make there own, and soon, people will be making a difference. Even a small positive difference is better than none at all. It's not about comparing some small task that wouldn't make that much of an impact to something that has made a large impact. Do what you can to save the environment while it is still habitable, and do it NOW.
jessiep7 years ago
if you'd like your project included in the Sew Useful Contest, be sure to add a link in your Instructable to your sleeve's Etsy page.
drew.adc7 years ago
Good idea, but why not just buy one of the sleeves with bubble wrap already inside it? Then you don't have to cut or sew anything, just slide the laptop in.
AlisonEtsy7 years ago
Great idea. Those envelopes are STURDY!
Hey, great idea! I want to make one for my laptop out of USPS envelopes now. Only my cat has an obsession with Tyvek and would constantly lick it. It's weird. It'd be really easy to get some adhesive velcro to make a closure for the flap.
Or just sew some velcro on; I think the adhesive velcro might come off of the Tyvek rather easily.
I could see adding a strap to this..making it a messenger bag. Good idea
tiuk7 years ago
Cool idea. I found a leather sleeve at a Samsonite store for $6. I think it's meant to carry documents in, but it fits my laptop perfectly.