Introduction: Make a Custom Printed Double Sided No. 10 Business Envelope From a Sheet of Paper

Picture of Make a Custom Printed Double Sided No. 10 Business Envelope From a Sheet of Paper

This instructable will show you how to make a customized standard No. 10 size business envelope out of an 8.5"x11" sheet of paper. This instructable is useful in many different situations. You can use it if you want to:

- Make a custom envelope with printing on the flap, front and back sides, and even the inside. Great for greeting cards, invitations, promo mailings, or just for the coolness factor.
- Make envelopes that match stationery with special colors, patterns, or paper types.
- Print addresses on your envelopes instead of handwriting them, even if your printer doesn't handle envelopes.
- Just have a plain envelope. You've run out, and you don't feel like going to the store (or can't).
- Be uber frugal. A piece of paper costs less than an envelope, and a minute of cutting and folding is worth the satisfaction of saving money (and notching another instructable in your belt).

Estimated Time to Complete Plain Envelope: Approximately 1 minute (once you know the process)

We'll go over how to make a plain envelope first. A double side printed envelope uses the same template and process, but you need to edit the template with a graphics program.

Step 1: Materials

Picture of Materials

This instructable uses very basic materials. You will need:

- The attached PDF files
- Scissors (or hobby knife suitable for cutting paper)
- Glue stick (preferred) or white glue
- Letter size (8.5"x11") sheet of paper. Heavier bond paper makes for a better feeling envelope.
- Printer
- Ruler (optional: can help with folding)

Please save or open the PDF files now.

Step 2: Print Out Templates

Picture of Print Out Templates

There are two different templates.

One is entitled envelope_template.pdf : this file is best for making a basic envelope as it includes visible folding lines. You fold inwards and the lines are no longer visible. Please print this one out now.

When you go to the print dialog box, ensure that there is no page scaling, or your envelope will be the wrong size. Choose the option to auto-center. Print. This screen shot is from Adobe Acrobat 3D.

The other one is entitled envelope_template_no_fold_lines.pdf . If you do custom graphics, you will have to fold outwards, thus making the fold lines visible and undesirable. You can use this one later.

Step 3: Cut Out Template

Picture of Cut Out Template

You'll notice that when you print out your template, the cut lines stop early. This amount will vary based on your printer's printable area (most printers have a margin where they are unable to print).

All of the cuts are straight lines, so you can just imagine the lines extending to the edge of the paper.

Cut out the sections as shown. When cutting, make sure to remove the printed cut lines with your cut so that they are not visible on the finished product.

Step 4: Fold Cut Templates

Picture of Fold Cut Templates

Next step is to fold the template. Since we want to hide the fold lines, fold inwards. I recommend folding the side flaps first.

Then, fold the bottom flap upwards.

The last fold is the top flap that you use to seal the envelope. There is no fold line (it would be visible), so imagine a line going across from the very top corners of the side flaps. Make sure to line this fold up well as it is apparent if it is crooked.

Step 5: Glue Side Flaps and Bottom

Picture of Glue Side Flaps and Bottom

Open the top flap back up, and the bottom flap back down.

With your glue stick, apply a line of glue near the sides of the bottom flap from the fold to the angled corner. This line of glue will adhere to the side flap, which conveniently is approximately the width of a glue stick.

When you have a line of glue on both sides, fold the bottom flap back up and smooth to bond the glue joint.

Congratulations! You just finished your plain envelope. All that is left is stuffing it with whatever you are mailing, and closing the top flap. You can either use a thin line glue stick line (hold at an angle and use the edge) or a piece of tape or a sticker to close the flap.

Proceed to the next step to learn how to make exciting graphics on your envelope.

Step 6: Step 0: Optional Graphics

Picture of Step 0: Optional Graphics

The real fun in this instructable is making creative and graphically pleasing envelopes in a way that no other method will allow you to. Import the envelope_template_no_fold_lines.pdf into your favorite graphics program (we used Adobe Photoshop CS), and add graphics as you see fit. Try dragging and dropping the icon for the file if you can't figure out how to import, many programs will work automatically.

Note: If you really need fold lines and custom graphics, you can print the envelope_template.pdf on one side of the paper, flip, and print the edited envelope_template_no_fold_lines.pdf on the other side.

Things to Remember:
- Flipping the paper and printing the template twice can also allow you to have printing on the inside of the envelope.
- The flaps fold, and thus their graphics must be upside down. Try working with the right side up graphics first, then rotating the whole image 180, and then working with the upside down graphics.
- When you print your edited template, it must be to scale or your envelope will be the wrong size. If your graphics program presents a problem and forces an autoscale, try printing to a PDF file first, then printing the PDF file using the method listed in step 2.

The sky is the limit, take an artistic license and let your creativity run free.

Thanks for reading, and we hope that you use this instructable many times in the future.

Comments

ANDRELAS (author)2017-07-31

Those sloping "shoulders" leave gaps where the flap meets the corners. Cutting the end flaps at 90° at the top gives a better seal.

MasterShifu (author)2017-01-27

Made a Chinese New Year red envelope for my girlfriend.

Thanks!

ShamanicHarmonics (author)2015-01-21

FANTASTIC - thanks!!!

Boclair (author)2015-01-18

great job & thanks!

Boclair (author)2015-01-18

great job! Thanks!

dwhite0 (author)2014-08-05

In your instructions you have 1 & 2 the same and again in 1,2. & 3. Also, your sealing flap is a little short. My flap might be short due to printing error, but your repeating instructions are there.

ggarnier (author)2014-05-21

From the write-up:

"You've run out, and you don't feel like going to the store (or can't)."

Exactly my situation today, mail pickup an hour away, needed to mail. I knew Instructables would come through for me. I made one!

pmn9393 (author)2010-08-15

This is kinda pointless, because most printer nowadays can print onto standard envelopes. Its just a switch to change paper thickness, or a built in sensor.

wenpherd (author)2008-12-16

is it possible to use GIMP or google sketchup

Mideeeacres (author)2008-09-06

Great idea for those of us that forget envelopes while travelling. Thanks!

PhilMuckracken420 (author)2008-01-07

sick dude

mathteacher (author)2008-01-05

Great idea!

ChuckNorris (author)2008-01-04

WOW if i didn't intimidate paper into folding themselves into letters i would so use this

mammie1956 (author)2008-01-03

What a great site to browse for projects that appeal to high school students. And as far as entering the contest to benefit your program, I applaud your motivation and creativity. Good Luck!

Happyman3444 (author)2008-01-03

Great step by step instructions

jimmyp23 (author)2008-01-03

good point on the anti-aliasing...

jimmyp23 (author)2008-01-03

very precise, thanks!

WBMASON (author)2008-01-03

good directions

WE ARE SORRY (author)2008-01-03

good job!!

cjg1313 (author)2008-01-03

This is great idea with very user-friendly directions. Try it!

teacher4life20 (author)2008-01-03

good idea, very easy to follow and easy to make, good job, also works well wen im out of envelopes

Tony Harivnak (author)2008-01-03

Excuse me' references to family guy are forbidden and punishable by 23 extended detentions(Huge Lisssssp)

mpg2245 (author)2008-01-03

this is by far the most incredible set of directions I have ever come across, the directions are so clear and precise YEA BY THE WAY JOHNNY CASH IS NOT COOL AT ALL

turtle12 (author)2008-01-03

yea way easier than printing on the envelope. I recommend trying it!

steveneagles311 (author)2008-01-03

its very good i love it. you must be a teacher..

JohnnyCash84 (author)2008-01-03

Cool idea. Much better than dealing with trying to print on an envelope.

teachme55 (author)2008-01-02

Very good idea, are you a engineering teacher? I may try this with my tech drawing students

Yes. 'We' refers to the two engineering instructors and the students at Hanover High School. We use instructables for projects on occasion (right now we are building 70+ Mousey the Junkbots) and we stumbled across the laser cutter contest just before it was too late. We put together our best effort for it and are crossing our fingers because a laser cutter is something that would greatly benefit our program. Designing an envelope is a great project that works well with most CAD programs (or even hand drawing if your doing that, though mirroring the folds in CAD helps alot). Its useful and fun. Now that we've made our first instructable, we'll being posting more in the future. Check back under our username in the future for any updates.

Cornflower (author)2008-01-02

Truly Excellent concept! I don't have Photoshop or a PDF editor, so I recreated the template in EVE (the Embedded Vector Editor, a 75k portable image editor) instead of .pdf Others might want to make templates in WordPerfect, Word (OpenOffice) or whatever they are comfortable with.

Weissensteinburg (author)2008-01-01

Those look great! Did you make the stencil, or did you get it somewhere?

We made the stencil in Autocad and then exported to PDF. In one of our classes (CAD I), students will be designing more sizes and different layout patterns. Successful ones will be added to the instructable when they are complete.

GorillazMiko (author)2008-01-01

Awesome job! Looks great, first couple of pictures are awesome, nice job putting on the Robot and stuff.

Thanks! A creative mind can really go crazy with this, as you can do images that extend around the edges and across the flaps. You can even have a peek-a-boo type effect by having a statement go from the outside of the flap...and then finish on the inside. It can turn out to be very cool.

About This Instructable

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Bio: We are a high school engineering program dedicated to applying math and science principles to projects and competitions.
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