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Interlocking-flap message envelope

Interlocking-flap message envelope developed as a fixed-size paper pattern with separate cut, fold and joining marks. Use the stated drawing sizes and make an empty trial before choosing material or contents.

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Paper
US Letter
Pages
3
Sheet
215.9 × 279.4 mm
Format
Print PDF
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Pages in this PDF
  • Page 1 — Assembly instructions
  • Page 2 — One-piece envelope net
  • Page 3 — Assembly instructions

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Interlocking-flap message envelope / LETTER

A good fit for your idea?

Letter and A4 preserve the component dimensions. Choose the sheet you will print, not a different object size.

Materials and construction

Plain paper for a first trial, a ruler, scissors and a blunt scoring tool; adult help for internal cuts.

Before making a batch

Measure the 50 mm reference and at least two named panel dimensions.

Assemble an empty plain-paper trial; record closure, seam, clearance and material behavior.

Inside this edition

Instruction pages
2
Orientation
Portrait

Envelope front and back panels: 86 x 58 mm. Side joining flaps: 12 mm.

No postal, archival, chemical barrier or negative-storage claim is made.

From file to finished page

  1. Cut the complete envelope net, keeping both shaded side tabs attached. Score the four panel boundaries.
  2. Fold the side tabs inward, then fold the back panel over them. Apply adhesive only to the shaded side tabs and leave the top opening clear.
  3. Cut the single 24 mm receiving slit in the back panel before assembly.
  4. Fold the top flap down and gently insert its 22 mm tongue into the receiving slit. Keep the tongue and slit free of adhesive.
  5. Dry-fit an expendable paper insert and open the closure repeatedly. Keep adhesive away from the insert and do not force a tight fit.
Printing and use notes

Nominal drawing dimensions are not a tested usable-capacity, load, mailing, food-contact or archival specification.

Do not place valuable, wet, hot or breakable items in an unreviewed paper prototype.

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Interlocking-flap message envelope