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Expandable document envelope

An expanding pocket with 90 x 120 mm faces, 12 mm accordion side/bottom gussets, and a 28 mm closure flap.

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All exact editions
Paper
US Letter
Pages
3
Sheet
215.9 × 279.4 mm
Format
Print PDF
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Pages in this PDF
  • Page 1 — back and flap
  • Page 2 — front; side gusset (2 pieces); bottom gusset; corner patch (2 pieces)
  • Page 3 — Assembly instructions

Enter these page numbers in your PDF viewer’s print range. Keep any instructions, matching answers and required project pieces.

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Expandable document envelope / LETTER

A good fit for your idea?

Choose the exact edition first. Its preview, pieces, paper size and instructions belong together; no physical fit or assembly approval is implied.

A pocket for small inserts, not a full sheet

The faces define a small wallet. Keep the contents shorter and narrower than the nominal panels so the folded gussets can move without scraping the insert.

Side and bottom gussets must remain free of adhesive inside their V folds. Use the small corner patches to close gaps, not to lock the moving folds together.

Inside this edition

Instruction pages
1

An expanding pocket with 90 x 120 mm faces, 12 mm accordion side/bottom gussets, and a 28 mm closure flap.

From file to finished page

  1. Choose the paper size loaded in your printer and open the matching PDF.
  2. Print the matching paper edition at actual size (100%). Measure the printed 50 mm line before cutting. The screen preview is not a measurement test.
  3. Cut the back/flap panel, separate front and three gusset strips. Keep every shaded 6 mm attachment tab.
  4. On each side strip, fold at 6, 12 and 18 mm across its width. The 6 and 18 mm lines attach to the faces; the 12 mm line folds inward to form the V-shaped expansion.
  5. Attach the outer tabs of each side gusset behind the corresponding left/right edges of the front and back. The side gussets stop 6 mm above the bottom so their folds do not collide.
  6. Form the bottom strip in the same way and glue its tabs behind the bottom edges. At each bottom corner, use the supplied small paper patch outside the seam, without filling the moving V fold with glue.
  7. Crease the top flap at the marked line and close it over the front. Use a removable paper band or a separate fastener of your choice; neither is implied by the blank flap.
  8. Check with an 80 x 110 mm scrap insert before using the envelope. It is a small document pocket, not an A4/Letter filing envelope.
Printing and use notes

The dimensions describe the flat pattern and fold lines, not guaranteed internal capacity.

Physical printing, fit and assembly have not been tested. Make a scrap-paper trial before using special stock.

This is a decorative or organizational paper project, not protective shipping packaging, food-contact material or a load-rated container.

Direct PDF files for every edition
  • Expandable document envelope / LETTER · 3 pages
    Page numbers and contents
    • Page 1 — back and flap
    • Page 2 — front; side gusset (2 pieces); bottom gusset; corner patch (2 pieces)
    • Page 3 — Assembly instructions
  • Expandable document envelope / A4 · 3 pages
    Page numbers and contents
    • Page 1 — back and flap
    • Page 2 — front; side gusset (2 pieces); bottom gusset; corner patch (2 pieces)
    • Page 3 — Assembly instructions

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Expandable document envelope