Custom #10 Envelopes
Custom printed #10 envelopes from 100 — the 4 1/8 × 9 1/2 in business envelope for letters, invoices and statements, plain or with a standard window, gummed for inserting machines or peel-and-seal for hand mailing, printed with your return address and mark.
The envelope a letter-size page folds into
- Paper
- 24 lb or 28 lb white wove; kraft and colored stock on request
- Size
- #10: 4 1/8 × 9 1/2 in
- Windows
- None, standard single, double, custom position
Get a price for 10 Envelopes
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Regular or window
If the letter is laid out to the standard window, any stock window envelope works; a custom window is worth it only when the form cannot move.
| Regular | Plain face; address printed or labeled; return address top left |
|---|---|
| Single window | Standard window about 1 1/8 × 4 1/2 in, 7/8 in from the left, 1/2 in from the bottom |
| Double window | A second window top left shows the sender block; for invoices and statements |
| Custom window | Positioned to your form; send the letter layout |
Gummed or peel-and-seal
- Gummed (moisture-activated) flaps suit inserting machines and are the cheapest.
- Peel-and-seal has a release strip; the choice for hand mailing in an office.
- Self-seal latex flaps press closed with no strip; common for bulk hand-packed mail.
Keeping the post office happy
Postal machines read the address and print a barcode along the bottom right of the envelope. Keep that strip clear — no logos or tint there — and keep the return address in the top left. Colored envelopes and dark inks can slow automated sorting, so light stock with dark print is the safe choice for business mail.
Check the current postal guidance for machinable letters if you mail in bulk; we lay the envelope out to the clear zones you specify.
Stock and security tint
24 lb white wove is the business standard; 28 lb feels heavier in the hand. A printed security tint inside hides the contents of invoices, checks and statements against the light, and can carry your own pattern. Matching letterheads are printed on the same stock family, and our letterhead printing on matching stock is set up to go with it.
Print on an envelope
Most business envelopes are printed one or two spot colors: a logo and a return address in the top left, sometimes a line on the flap. Full color works too. Print that runs across the seams of a converted envelope needs a slightly different setup from a flat sheet, so tell us if the design wraps around the edges.
10 Envelopes — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Paper
- 24 lb or 28 lb white wove; kraft and colored stock on request
- Size
- #10: 4 1/8 × 9 1/2 in
- Windows
- None, standard single, double, custom position
- Flaps
- Gummed, peel-and-seal, self-seal
- Inside
- Plain or security tint, standard or custom pattern
- 1–2 spot colors or full color
- Minimum
- 100 envelopes
On every job
- Print process
- Digital below about a thousand, offset above it. Both sides as standard on cards, tags and leaflets.
- Color
- CMYK with spot colors for a brand match. Uncoated and cotton stocks print noticeably lighter than coated ones.
- Tolerance
- Trim plus or minus 1 mm guillotined, plus or minus 0.5 mm die-cut. Anything over about 170gsm is creased before folding.
- Tooling
- A die only where the piece is shaped, perforated or drilled, made once and kept. A plain rectangle needs none.
- Food contact
- Food-safe inks on menus and counter print that will be handled where food is served.
- Sustainability
- Uncoated and unlaminated stocks recycle without separation, and FSC papers are available across the range.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build 10 envelopes on
Sheet print is judged in the hand more than a box is: the weight, the surface and whether a pen works on it. These are the stocks we run for cards, folders, leaflets and stationery.
Coated card 300–400gsm
The workhorse. Sharp full-color print, matte or gloss, laminated where it is handled. Does not take a pen unless the finish is matte.
300–400gsmUncoated card
No clay coat. Colors read softer and warmer, a deboss goes deeper, and it writes on with anything. Photographs lose punch.
300–400gsmCotton and textured card
Soft, thick and fibrous. Takes a deep blind deboss and reads as an invitation. Foil sits beautifully; four-color does not.
400–700gsmDuplexed card
Two sheets bonded, often with a colored core, for a very thick card with a visible colored edge. The heaviest thing we print.
600–900gsmText paper 100–170gsm
Leaflets, folder inners and booklet pages. Folds without cracking and takes a full-color print on both faces.
100–170gsmManila and kraft paper
Unbleached, tan, and cheap. One or two colors read well; white ink gives a light mark. Envelopes, folders and tags.
90–300gsmSynthetic stock
Polypropylene sheet for tags and cards that get wet, torn or handled outdoors. Prints like paper and does not soften.
200–400 micronBoard-backed
A printed face laminated to grayboard, for a rigid card, a folder back or a display that has to stand up on its own.
1–2 mm boardNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Sheet print takes the widest range of finishes of anything we make.
Matte lamination
Soft, fingerprint-resistant, and it still takes a pen. The default on anything handled.
Gloss lamination
Maximum color depth. Shows every fingerprint and refuses a ballpoint.
Hot foil
Gold, rose gold, silver, holographic or a color. The block is small so the die is cheap.
Emboss and deboss
Deepest on uncoated and cotton stocks; shallow and prone to cracking on gloss coated.
Spot UV
A gloss shape on a matte laminate. Best on a dark ground where the contrast reads.
Edge paint and colored core
Color on the cut edge of a thick or duplexed card. Only seen when the card is picked up, which is the point.
Soft-touch
A velvet laminate on a cover or a folder. Marks on white; excellent on dark.
Uncoated and textured
No film at all. Writes on, debosses deeply, and reads as considered rather than cheap.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing printed sheets, folds and the grain: 10 envelopes
A printed piece is specified flat and finished folded, and the difference between the two is where mistakes live. Send the finished size you want and we work back to the flat.
- Finished size
- The size after folding and trimming. A6, A5, A4, DL, US letter and legal are standard; anything else is cut on its own die.
- Bleed and safe area
- 3 mm of artwork past every trim edge, and nothing important within 4 mm inside it. The guillotine drifts by a fraction on every stack.
- Grain direction
- Paper folds cleanly along the grain and cracks across it. We set the grain to the fold, which is why a sheet is not simply cut from the biggest sheet available.
- Fold allowance
- On a roll fold or a gate fold, the inner panels are cut a millimeter or two shorter so the piece closes flat.
- Creasing
- Anything over about 170gsm is creased before folding. Without it the fold cracks and the coating flakes along the line.
- Trim tolerance
- Plus or minus 1 mm guillotined, plus or minus 0.5 mm die-cut.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Spec your 10 Envelopes
Pick a shape, type a size, choose a stock and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about 10 envelopes? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What size is a #10 envelope?
4 1/8 × 9 1/2 in. It takes a letter-size page folded in three.
Where is the window on a #10 window envelope?
The standard window is about 1 1/8 × 4 1/2 in, 7/8 in from the left and 1/2 in from the bottom.
What is a double window envelope?
One with a second window at the top left that shows the sender block from the letter.
Gummed or peel-and-seal?
Gummed for inserting machines and the lowest price; peel-and-seal for hand mailing.
What is a security tint?
A printed pattern inside the envelope that stops the contents being read through it.
Which paper weight should I choose?
24 lb white wove is standard; 28 lb for a heavier feel.
Can I print in full color?
Yes, though most business envelopes use one or two spot colors.
Where should the logo go?
Top left with the return address. Keep the bottom right strip clear for postal barcodes.
Can you match my letterhead?
Yes, on the same stock family with the same colors.
Do you make custom window positions?
Yes. Send the letter layout and we place the window to it.
What is the minimum order for #10 envelopes?
100 envelopes. Window and regular versions of one design can be ordered together.
How long does it take to print #10 envelopes?
Printing on stock envelopes is quickest; custom windows or security tints add steps. We give a date with the quote.
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