1 Piece Tyvek Wallet




Tyvek® is an extremely light and tough material. Tyvek® is a material created by Dupont and is used in many application today, including envelopes, banners, and house weather screening.

This instructable is for a 1 piece, no tape, bi-fold wallet. The wallet will have 1 money slot and 2 credit card slots.

Step 1: Get the Envelope

I found this step the hardest. The USPS, Fedx, and DHL use Tyvek envelopes. I know the USPS and Fedx give away the envelopes for free. I asked nicely at my local USPS and they gave me a bunch of them.

Step 2: Template/Measurements

These picture is of the measurements, also attached is the E-machine shop file.

Step 3: Photo Step by Step

Descriptions Are Written on the Photos

Step 4: Video

Step 5: Well That Is It.

Just fold and you are done. You don't need to make it out of tyvek, card-stock and paper are other options.



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    10 Discussions

    IAmArtPVC marxman

    Reply 8 years ago on Introduction

    FYI - There is a legal disclaimer on USPS pouches indicating that misuse of their pouches may be a federal violation and that they belong to the USPS.


    10 years ago on Introduction

    You diagram provides a good template, though I did find that I had to make several adjustments to make the wallet fit my preference:
    (1) I used a 12x15" envelope (priority mail, same as your's I believe)
    (2) I used both sides and kept them connected ... that is, the edges parallel to the text were not cut, which basically doubled the tyvek paper for a, hopefully, stronger wallet.
    (3) The measurements you included resulted in a somewhat taller than desired wallet ... I wanted mine to be nearly the exact height of a dollar bill, maybe just a bit shorter even ... that makes the credit cards fit more snugly and prevents them from falling out while still allowing many cards (including a dozen business cards with room for twice as many.

    To get the shorter height (closer to the height of a dollar bill along it's short sides), and because I used a piece that was actually 12" tall (your diagram calls for (3 x 3.5) + (2 x .125) = 10.75"), I had to make some of the folds a bit longer, particularly, the .5" fold at the bottom became a 1.25", and I had to add a fold at the top that is ~.75" and folded into the dollar bill pocket. This also frames the "priority mail" text and blue stripe nicely.

    Also, taking an idea from the "Super Thin Tyvek Card Sleeve Wallet! by marksbrenSuper Thin Tyvek Card Sleeve Wallet! by marksbren" I put a rounded cut into the credit card pockets and a thumb slit on the interior to allow me to push the cards out with one hand.

    I'll add a couple photos later, this was a very helpful design!


    11 years ago on Introduction

    how do you keep the cards from sliding out? TyVek is too slick, and my cards fall out, what could I put in to help provide some friction?


    12 years ago

    FANTASTIC!! I made one with a FedEx envelope and made some measurment changes, the card slots seemed too big with your measurments but otherwise very nice.


    12 years ago

    I love the 2nd pic with the caption around your brother's feeble attempt to tear the Tyvek envelope. I guess you'll just have to tear him a new one, no?


    12 years ago

    This is really cool-- but could you possibly add a photo step-by-step? It'd be a bit easier to follow.

    1 reply

    12 years ago

    Cool. I currently have a duct tape wallet but if i get around to getting a Tyvek envelope i think i'll switch.