Envelope template
Set the dimensions. Check the folds. Make a small test box.
Flat panel guide
Assembly
- 1
Cut the outline and score the body edges.
Flat panel guide
- 2
Fold the side glue flaps inward.
Folded assembly guide
- 3
Raise the pocket flap and check its overlap.
Folded assembly guide
- 4
Glue the pocket only where it meets the side tabs.
Folded assembly guide
- 5
After drying, insert the contents and fold the closing flap.
Folded assembly guide
Measure everything that goes inside
Use the combined width and height of the card, note and insert in their intended orientation. The clearance is added at every edge. This envelope is a flat construction; it has no freely adjustable box depth, so a bulky stack needs a trial rather than a claimed capacity.
A 100 × 70 mm insert with 2 mm at each edge gives a 104 × 74 mm body. In the design example, 12 mm side glue flaps, a 40 mm closing flap and a 60 mm pocket flap form a 128 × 174 mm flat envelope.
Keep glue outside the usable area
Score the body rectangle and fold the side flaps inward. Bring the pocket flap over them and check the overlap before applying adhesive. Glue only where those flaps meet; a line of glue across the pocket can reduce the usable space or catch the insert.
Try the insert once the pocket is dry. It should enter without bowing the front panel. Close the top flap last and check that it covers the opening without catching the card.
Test the blank before finishing it
Mark the outside on a scrap prototype before adding artwork. Fold the closing flap to check which portion remains visible. A longer flap changes appearance and overlap, not the pocket's base dimensions. Keep the final paper and the trial similar in thickness if the contents are a close fit.