Free custom envelope template generator

Enter the card or insert, not an envelope standard

Measure the finished card or insert that must slide into the pocket: width across the card, height along it, and the requested closing-flap depth. If the contents are layered, measure the whole stack and include embellishments that cannot compress. ExactFold does not select a commercial envelope size and does not calculate a window position; the template is a custom folded outline around the dimensions you provide.

• Use width and height for the card or insert in the generator fields.
• Depth is the flap-depth input for this route, expressed in the selected units.
• Prototype with the actual paper stack before buying envelopes or final stock.

How the custom envelope outline is formed

The generator derives side width from 72% of the flap-depth input, with minimum and maximum bounds based on the card width. It also bounds the top flap at the depth input and the bottom flap at 115% of that input. The result is one closed cut outline with four straight fold paths: top, right, bottom and left. No glue path is emitted, so the drawing does not prescribe an adhesive seam or a window.

side = clamp(0.72 × depth; 10; 0.42 × card width); bottom flap = clamp(1.15 × depth; 16; 0.85 × card height)

Cut the outline, then fold the four flaps

The solid perimeter is the cut line. The four internal lines are folds that define the side flaps, bottom flap and top closing flap. Score before folding, bring the side flaps inward, fold the bottom flap over them and use the top flap as the closure. Because the generator supplies folds rather than a glue path, choose an adhesive, sticker or seal that suits the paper yourself; there is no built-in envelope window or dieline standard.

• Keep the diagonal shoulders of the outline intact when cutting.
• Dry-fold once to check that the card clears every corner.
• Seal only after confirming the insert can still be removed.

Worked example: a 160 × 110 mm card

For a 160 mm wide by 110 mm high card with a 42 mm flap-depth input, the side rule gives 0.72 × 42 = 30.24 mm, which stays inside its bounds. The top flap uses the 42 mm input, while the bottom rule gives 1.15 × 42 = 48.3 mm before its bounds are applied. These values control the outline’s shoulders and flap reach; they do not promise a recognised C6, DL or other retail envelope size.

side = 0.72 × 42 = 30.24 mm; bottom flap = 1.15 × 42 = 48.3 mm

Print without shrinking the card pocket

Choose A4 or Letter and inspect the page count before downloading. Print the PDF with 100%, Actual Size or No Scaling, then measure the included 50 mm calibration ruler. Fit-to-page scaling can remove the clearance you measured for the insert. SVG preserves the real-size vector paths for a cutter or design program; DXF is a millimetre-based exchange file. Check import units and leave the cut and fold operations separate.

When a custom envelope needs another test

If the card catches at the shoulders, recheck the stack thickness and print scale before changing the flap input. Heavy paper, rounded corners, coatings and decorative layers can need more room than a flat measurement suggests. ExactFold does not model paper grain, glue thickness, window film, postage requirements, water resistance or commercial envelope regulations. Treat the first print as a fit check and do not infer a certified mailing format from the generated outline.