NOTES FROM THE WORKBENCH
An envelope for a card and an insert
Treat the card and its extra sheet as one set, then keep the glue outside the pocket they need to occupy.
Reviewed October 27, 2026
Measure the finished stationery
A folded card has a spine and can spring open slightly. An extra printed insert may extend past the nominal card edge. Put them together in the orientation they will be placed in the envelope before measuring.
The envelope model describes a flat pocket. It does not have a separate box-depth field that can guarantee room for a thick stack. If the contents bow the paper substantially, try a deeper box or a sleeve around a suitable inner package.
Add space at the edges
In the example, a 100 × 70 mm insert receives 2 mm of clearance at every edge, producing a 104 × 74 mm body. The calculation adds the allowance twice to each full axis. It does not imply that all stationery needs exactly 2 mm.
Choose a practical allowance for the actual paper and edge finish. A delicate card may need more space for safe removal than a smooth rigid insert. Keep the measurement of the original contents so you can tell later whether you changed size or allowance.
Glue the side overlaps carefully
Score all body boundaries and dry-fold the side tabs and pocket flap. Check where the tabs meet the lower flap before adding adhesive. A line of glue outside that overlap can close part of the pocket and make a correctly sized body unusable.
Let the pocket dry before inserting the card. Check the bottom corners for stray glue and try removing the set without flexing it sharply.
Check the top flap last
Fold the closing flap with the full set in place. It should cover the opening naturally rather than pull the front panel into a curve. Mark the outside on the trial before positioning artwork.
Save the envelope dimensions alongside the stationery set's measurements. If the insert changes paper or becomes folded, revisit the trial instead of relying only on the old flat width and height.
Ready to make something?
Set the dimensions. Check the folds. Make a small test box.