Here, at a much smaller scale (and hopefully not running afoul of the DMCA) here's a way to turn a Tyvek envelope into a wallet. I'm using a FedEx envelope, but you can use any Tyvek envelope 8" x 10" or larger.
There are many other Tyvek wallet instructables, but this one has a few advantages:
- It does not require any measuring, sewing, or additional adhesives.
- It uses almost 100% of the envelope, resulting in very little waste.
- It requires only two cuts with a pair of ordinary scissors.
- It can be completed in 5 minutes by someone familiar with the folds.
(Video below has no audio.)
Step 1: The First Cut
Fold the envelope into eights - quarters across the wide axis, and half along the wide axis.
Invert one half of the envelope into the other, then cut an opening one-quarter the width of the envelope.
Un-invert envelope and flatten.
- Envelope folded into quarters along the wide axis
- Envelope divided into eighths. Permanent marker lines added for visibility, not required.
- Half of envelope inverted into itself,
- One-quarter width slot cut out of envelope. In this case, we are preserving the logo, but that's purely an aesthetic concern.
- Un-inverted and flattened envelope showing slot.
Step 2: The Tough Part: Sink Fold
A sink fold in origami is when you invert the paper on both sides so a protruding portion of the paper is turned inward.
Here, we make a diagonal at the halfway-width of the envelope to show ourselves how far the side of the envelope needs to be inverted.
Once we invert one side, we fold the other edge down as a diagonal and invert it as well.
- Fold the diagonal at half the width of the envelope.
- Sink that side into the envelope.
- Fold the other diagonal.
- Both sides of the envelope sink-folded into itself.
Step 3: Sealing It Up
Once we've smoothed out the sink fold's interior corners, we seal the envelope.
We fold it in half and the newly-sealed section in two. The cut is rounded for aesthetic reasons. A simple slit will work as well.
- Unfolding the diagonal folds.
- Sealing the envelope. It helps to pre-fold the flap, not shown.
- Sealed envelope.
- Envelope folded in half with slot cut out.
- Envelope unfolded to show slot.
Step 4: That's All, Folks
Bank and identification cards go in the pockets formed by the first slit.
Paper currency can go in the longer pockets open to the top, or can be secured by the two flaps we just cut.
The flaps themselves can seal either cards or coins.
- Wallet showing card storage side pockets.
- Wallet showing paper currency storage with securing flap.