Creating my own custom envelope

We have a huge range (600+) of envelope sizes and colours - so there's plenty of choice on our warehouse shelves!

Our envelope machines are designed to run tens-of-thousands of envelopes at a time, turning them from flat die cut shapes, folding and gluing to the final product - it's quite a sight to see it in action!

But sometimes, you may want to create an envelope in a slightly different size, or with a unique flap or closure. Creating small quantities of envelopes isn't possible with this machinery, but you can create your own custom die line and have your envelopes digitally die cut instead!

Top Tips from the Printery Peeps

• The largest flat size your die line can be is SRA3 (A3 if your design on the envelope requires bleed). It's possible to create up to a C5 (229x162mm) size.
• To understand envelope construction, do some online research or deconstruct an envelope to see how it works.
• You can digitally print including variable data just like our off-the-shelf envelopes.
• Follow our instructions to set up your custom die line correctly.
• Order a sample custom die cut to test the construction, we can't tell you if your design will work the way you intend it to.
• Custom die cut envelopes are supplied flat, ready for you to glue and assemble. Contact Customer Service if you'd like a quote for us to assemble them for you.

Digital die cutting is a brilliant cost-effective way to make a custom envelope, although please note that the scoring is not quite as crisp as a physical traditional die.

If you want more than 100 pieces or would like to use the die line again and again, it's probably worth investing in a traditional die. 

Traditional dies are also required if you would like Hot Foil Press or Embossing on your custom envelope. Contact Customer Service if you'd like a quote for custom dies to use with Hot Foil Press or Embossing designs at this large size to check the artwork suitability.