Note: If you can find one with a clear window, you could somehow utilize that portion to display your drivers license once assembled, but the cutting would need to be modified for this purpose.
If anyone can add to this design, I would love the feedback. Ideally it would be better to be able to fold the envelope and only do a few cuts. Maybe someone with origami knowledge can help us with this idea?
Step 1: How to cut the envelope
1 tyvek mailing envelope ( new or recycled )
1 pair of scissors ( or x-acto knife )
1 ruler ( metric )
Optional: Clear packing tape if using a recycled envelope
The first image shows how to cut the envelope into its main parts: A - B - C - D ( D has a qty 2). Measurements are in mm. The adhesive strip is shown cut into its parts, which is optional.
Note: Cut adhesive strip LAST! This really gums up your scissors / knife. The adhesive will need to be cleaned off with a solvent such as fingernail polish remover ( Wear gloves and goggles people! )
Cut along the lines as shown. You will end up with part A that is 90 mm tall and is the main bill pocket. Note that it is already nicely sealed on 3 sides so your bills don't stick to any tape. You will also end up with Part B which is the secondary pocket 70 mm tall, and part C the inside of the secondary pocket 60 mm tall ( B & C are now really just a folded piece of tyvek once they are cut apart from the envelope ). You will have a quantity of 2 part D's, which are sheets of tyvek 120 x 200 mm. Left over will be a small amount of scrap plus the adhesive strip.