Picture of Tyvek Wallet
Let's make a simple, cheap, durable bifold wallet out of Tyvek (the housing wrap and express mail envelope material).

Please note: this is my first instructable.

Step 1: Materials and Pattern

Picture of Materials and Pattern
Materials: 6 x 14.5 inches Tyvek or fabric of your choice (duct tape, 1000 denier nylon, denim, rip-stop nylon, etc), 3 inches of elastic (almost anything will work), optional: zipper, velcro

You can either sew the wallet together (which I am doing), or tape it together with packing tape or duct tape or another suitable tape.

This is the pattern, all measurements in inches. No seam allowances are needed.

If this image is unreadable:
the main body is 6 x 7.5
the small flap is 0.75 x 2.5
the large flap is 2.5 x 4.5

[I posted the same text in another instructables link as well - to describe an issue I had]

Ok.... the reason why I'm posting here right now is - I got a shock and
surprise. I made a tyvek wallet several years ago. And several years
ago, the material was super strong. Several years later, I picked up
that wallet (having not used it at all) and simply pulled on the tyvek
clip-on buckle strap, and the material tore away from the buckle! Bad
news. The tyvek material had degraded and had become as weak as typical
paper. I was able to just tear the tyvek like normal paper. Not good at

Update: I have checked the stack of original tyvek source
material (stored in a yellow envelope) and I tried to tear it - cannot
tear it. Super strong. My guess is that the tyvek material might degrade
when exposed to light. Light contains U.V. So UV degradation could be
an issue.

sgsidekick8 months ago

I'm thinking maybe instead of putting the elastic band on the inside, you make a separate "sleeve" in the place, and attach the elastic so it can be slipped over the wallet when closed, to keep it shut.

awig11 months ago

nice tutorial, thank you!

This is a truly practical thing to do with tyvek material. A wallet made out of tyvek material is a really clever idea. I think that going just one step further - by adding a snap fastener to the tyvek wallet - can make it even more convenient to use, because the added snap fastener prevents the wallet from opening up undesirably. I made my first tyvek wallet very recently, and added a fastener.

dynomighty6 years ago

Its great to see such enthusiasm around tyvek - looks like a design I posted a couple years ago. I posted instructions and a video here if anyone is interested.

This video demonstrates how to make the Tyvek Envelope Wallet here:

Many years ago I was the original designer of the Tyvek Wallet called the "Mighty Wallet" which is now gaining popularity after years of marketing and hardwork. Its really cool to see this new trend in wallet design emerging into the limelight - THANKS!

You can see the Mighty Wallet on my website: www.dynomighty.com

You were one of the designers of Mighty Wallet! That's too awesome!
Have you tried using rip-stop nylon? Works a treat. Can be free if you live anywhere near a sailmaker, kitemaker or similar. We managed to get bin bags full of the stuff - Now have to try and find the money and cards to fill all the wallets we could make!
where do u get tyvek?
goldscott (author)  Zaphod Beeblebrox5 years ago
You can get 11x17 inch tyvek envelopes from FedEx and USPS, as well as UPS.

Large rolls of tyvek are used for housing wrap, but one of those rolls is probably pretty expensive.
jumpertoad5 years ago
berserk6 years ago
How durable is tyvek for this application? I had just a plastic sleeve for my licence and stuff but it's wearing out. It has lasted for several years, so how well does this hold up?
goldscott (author)  berserk6 years ago
I've had the wallet for about two months now, and so far so good. No rips or tears; looks the same as the day I made it. I noticed the Tyvek is getting a bit "softer," sort of like an old dollar bill. I like the feeling, though. I would assume that the Tyvek will easily hold up for a few years. I know those plastic sleeves generally rip apart at the seams; I don't think Tyvek will have that problem, especially if you sew it.