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Custom Envelopes
We are mainly a “Custom Envelope Shop”. Our flexible equipment allows us to manufacture a wide variety of envelope styles, sizes and configurations.
•          Diagonal Seam
•          Side Seam
•          WEB Envelopes
•          Open Side Envelopes
•          Open End Envelopes
•          Coin, Teller and Financial Envelopes
•          Booklets and Catalogs
Custom Envelope and Window Dies.
We have a very large inventory of Envelopes Dies as well as Window Dies to match your envelope construction. (Please feel free to review our Custom Envelope Dies List as well as our Single Window Die List).
Custom Envelope Die
Single Window Die
Double Window Die
(Please ask our Sales Rep for information regarding our Double Window Die List).
Inside Tint Patterns.
Stock Inside Tint Designs
At Texas Star Envelope we offer a variety of standard inside tints. Additionally, we can print your custom inside tint (Additional charges will apply for designing and producing custom inside tints). Let our team help you with any specific requirement you might have.
Need to design a new envelope or to modify some information on an existing one? Please let us help you!
We have full time designers, ready to assist you with typesetting services. Please ask your Customer Service Representative and we will be more than happy to help you.


Envelope Styles and Sizes


There are plenty of envelope types and sizes available — they differ by size, paper type, flap type, window (if any) and construction.


This picture illustrates various parts of an envelope. The variations of these parts create different envelope styles.


Parts of an envelope


The envelopes with the opening and seal flap located on the short dimension are called Open End envelopes. Those with the flap on the long dimension are called Open Side (Booklet) envelopes. Open Side (Booklet) envelopes are ideal for automatic insertion applications.



Flap Styles
The flap is the part of the envelope that is folded to seal the envelope. The main flap shapes are shown in the illustration.


Flap styles


Sizes and Styles

There are two main envelope standard systems we're going to review. The first is used in the USA (US envelopes are also often known as Standard), the other is the ISO metric system used in Europe and many other parts of the world. The envelope sizes may vary from tiny to huge, and there are dozens of them of sizes available. Though you'll hardly use more than 4-5 most common sizes in your everyday practice, it's a good to have an understanding of other possible styles and sizes.


Standard (US)

The US (or Standard) envelopes are divided in several groups by their style and application. The sizes are listed in inches, the shortest dimension first.



These are the most popular envelopes for business correspondence, that we send and receive every day. They usually have commercial flap.
They are mostly used for letterheads, invoices, statements, checks, writing stationery and direct marketing mailings.


 #  Size
 6 1/4  3 1/2" x 6"
 6 3/4  3 5/8" x 6 1/2"
 7 3/4  3 7/8" x 7 1/2"
Monarch  3 7/8" x 7 1/2"
 8 5/8  3 5/8" x 8 5/8"
 9  3 7/8" x 8 7/8"
 10  4 1/8" x 9 1/2"
 11  4 1/2" x 10 3/8"
 12  4 3/4" x 11"
 14  5" x 11 1/2"



Note: The 7 3/4 envelope with pointed flap is also known as Monarch.



These are very common envelopes. The flaps are usually pointed or flat.
Mostly used for announcements, invitations, cards, small booklets, brochures or promotional pieces.


#  Size
 A-2  4 3/8" x 5 3/4"
 A-6  4 3/4" x 6 1/2"
 A-7  5 1/4" x 7 1/4"
 5 1/2" x 8 1/8"
 5 3/4" x 8 3/4"
 6" x 9 1/2"







These envelopes are mostly used for sending catalogs, folders and the like.


 4 3/4" x 6 1/2"
 5 1/2" x 8 1/8"
 5 3/4" x 8 7/8"
 6 1/2
 6" x 9"
 6 1/4" x 9 5/8"
 7 1/2
 7 1/2" x 10 1/2"
 8 3/4" x 11 1/2"
 9 1/2
 9" x 12"
 9 1/2" x 12 5/8"
 10" x 13"



This style of envelope is mainly used for catalogs, magazines and reports.

 6" x 9"
 1 3/4
 6 1/2" x 9 1/2"
 6 1/2" x 10"
 7" x 10"
 7 1/2" x 10 1/2"
 8" x 11"
 8 1/4" x 11 1/4"
 9 1/2
 8 1/2" x 10 1/2"
 9 3/4
 8 3/4" x 11 1/4"
 10 1/2
 9" x 12"
 12 1/2
 9 1/2" x 12 1/2"
 13 1/2
 10" x 13"
 14 1/4
 11 1/4" x 14 1/4"
 14 1/2
 11 1/2" x 14 1/2"


There are also Metal Clasp, Coins, and other styles, which are not listed here because they are either rare, too small or too large or not suitable for printing (such as Metal Clasp).

Window Envelopes (US)

Window envelopes are most often used for bills, though they're also popular for marketing purposes. They are cost-efficient, since the name and address show through the window, eliminating the need to address the envelope. Normally translucent plastic is used as the window material. Open window envelopes are growing in popularity as more environmentally friendly, however, they are less secure.

Single-Window Envelopes

Theoretically, nearly each envelope type and size may have a window, this generally depends on the manufacturer. The most common (and recommended by USPS) window size is 1 1/8 x 4 1/2, and the position 7/8 in from left and 1/2 (often 5/8) in from bottom, but there are lots of variations.


Single-Window Envelope


Double-Window Envelopes
Such envelopes are often used for checks and invoices. The three probably most popular envelope sizes with double windows are:


Double-Window Envelopes


Note: The sizes and positions of windows may vary greatly, and depending on the manufacturer. There are no standards for these (at least which we are aware of).


ISO Envelope Standards
These envelopes are widely used all over the world. The C series was designed to accommodate ISO A paper sizes (see The ISO Paper Size Concept by Markus Kuhn). For example, a C5 envelope will accommodate an A5 sheet flat or an A4 folded once. The B series is an alternative, and is much less common than the C series. The sizes are provided in millimeters and in inches (for reference).


 Size, mm
 Size, in
 Content Format and Comments
 324 x 458
 12 3/4 x 18
A3 sheet; Not very common
 250 x 353
 9 7/8 x 13 7/8
C4 envelope
 229 x 324
 9 x 12 3/4
A4 sheet; Very common
 176 x 250
 7 x 9 7/8
C5 envelope
 162 x 229
 6 3/8 x 9
A4 folded once = A5; Very common
 125 x 176
 5 x 7
A4 folded in quarters; Very common
 114 x 162
 4 1/2 x 6 3/8
A4 folded in quarters; Very common
 110 x 220
 4 1/4 x 8 3/4
A4 sheet folded in thirds, A5 sheet folded in half lengthwise; Very common
 114 x 229
 4 1/2 x 9
A4 sheet folded in thirds; Common
 81 x 162
 3 1/4 x 6 3/8
A5 sheet folded in thirds; Uncommon
 81 x 114
 3 1/4 x 4 1/2
A5 sheet folded in quarters; Uncommon


Note: Although DL is not part of the ISO C series, it is a very widely used standard size.

Window Envelopes

There are no international standards yet for window envelopes. Some countries have set their own national standards, for instance:

Germany: The window is 90 x 45 mm large, and its left edge is located 20 mm from the left edge of the envelope. The bottom edge of the window is located 15 mm from the bottom of the envelope (for C6, DL and C6/C5 envelopes). For C4 envelopes, the top edge of the window should be either 27 mm or 45 mm from the top edge of the envelope.
UK: The window on a DL envelope should be 93 x 39 mm large, and located 20 mm from the left and 53 mm from the top of the envelope.

Addressing and Printing Guidelines

The correct formatting and address position on an envelope is required to facilitate mail processing by optical character recognition equipment, used by many postal services for sorting mail. Machine-readable mail can be sorted automatically, rather than by a human, which results in faster and more accurate delivery.

Here is the picture that illustrates the correct address position:


Address position


General Considerations
  • Always use the ZIP/Postal code.
  • If you're using software for printing addresses, always print barcodes if they are supported by the software.
  • Use simple fonts, such as Arial or Helvetica, and font size over 12 points.
  • Avoid using any graphics in the address zone, as it may confuse the optical reading equipment.
When printing addresses on envelopes or labels, it's recommended that you use a laser printer — ink from inkjet printers is susceptible to moisture, and the address may get blurred or even completely unreadable on the way. However, don't print on window envelopes with laser printers — the window material will melt because of the contact with the printer's heating element.