All you need to know about our Custom Envelope Printing
| | CheapRushPrinting Editorial Team
Attractive Envelopes That Get Opened!
When a prospect checks their daily mail, they see a sea of plain, white, boring paper. But if there is one custom printed, full-bleed design with vibrant color and a tactile feel, they will grab that one first. We ensure you are the one with the catchy envelope that demands to be opened.
Our Custom Envelope Printing service ensures your design is adequate to your products and company theme, creating a physical connection before the letter is even read. Getting the artwork prepared can be done in many ways:
- You can send us your final copy for us to print it.
- You may leverage from our free guideline pre-made files from template gallery.
- We can build a Free Setup for you.
- For more sophisticated designs, we also have the PAID version.
The Envelope Is Responsible for the 'First Impression'
Keep in mind that before anyone reads the important data inside, the first impression is triggered by the style, size, and tactile feel of the custom envelope itself. Never forget that the container sets the value of the content.
In 2026, physical mailing has already become a luxury touchpoint rather than a conventional communication channel. This is interesting physical details touch to your communication to provide visual likeness to your envelope printing for better, nicer interaction with your brand.
A regular white sleeve signals for 'utility bill' or 'junk mail', while a custom full color printed envelope will say 'opportunity'!
Let's talk about the 'Open Rate' study: Recently marketing signals providers conducted research to see what is the difference between sending communication with generic vs custom made graphics, and found an increase of 40% higher open rate, which Is considered a success already. Why is this? Because, little details count, a nice logo, a nice design, colorful layouts are relevant to your brand and logo, personal and professional.
There is an extra clever edge in our stationery that rely on printing them to look like 'FULL BLEED'. This means that there will be no white border around the paper, the entire surface can be designed and printed with flowing art that crosses from one folded section to the other. This will take us way apart from conventional prints.
The Custom Envelope Manufacturing Difference
Our process for high-fidelity envelope printing is distinct and follows three key steps:
- Envelope Print: We setup your design on a flat based design template first.
- Die-Cut: The custom printed piece is then die-cut to the specific ordered measures and envelope shape style.
- Convert: And finally, folded and glued to its final envelope form.
This is the method that allows the full-bleed envelope look that is a must have for top-open-rate conversion percentage to run in your favor.
Paper Science: Why "70lb" Stock Matters
Every paper has its purpose. While a cheap 20lb bond might work for billing, we hardly recommend the higher standard 70lb paper for a consistent, professional presentation. This avoids the "see-through" and disposable feel of lighter papers, ensuring your brand feels established and substantial in the customer's hand.
We offer out 70lb Opaque Smooth White stock paper as the best balance between luxury feel while keeping the price of production as low as possible for the customer. Here are some of what we call 'Gold Standard' for a finished professional looking stationary:
- Opacity (Privacy): The paper density prevents regular 'see through' situations, economizing the customer from having to purchase the 'security layer' envelope covers that prevents regular mail handler from viewing the content.
- Privacy Protection: This paper opacity helps to hide the documents information much better than regular bond light printed envelopes.
- Tactile Weight: 70lb Opaque paper compares to around 5pt thickness of paper stock, so it gives a substantial and strong thickness feel in your hand, suggesting 'there is something worth looking at inside the custom envelope!"
- Smooth Uncoated Finish: Rather than being shiny and call attention through the use of gloss surfaces, we rather keep the stationery practical and writeable.
- Writeable Surface: In many occasions the custom envelopes and final designatory find themselves with the need of writing stuff on the surface, instructions, phones or any other note. The uncoated finishing is perfect to allow writing without issues and ink smudging.
- Brightness: The brighter the paper, the nicer the colors printed on it will look, this ensures your logo, images and overall envelope design to pop-up colors to contrast sharply against the paper.
Commercial Envelopes Perfect For Every Industry
All industries can leverage from custom printed envelopes, from the corporate boardroom to elegant wedding events. You can tweak the size, design, and colors to dictate the exact tone of the message you want to transmit. We offer a huge variety of business and commercial stationery in various sizes for every occasion:
Corporate & Financial (#10 & #9 Envelope Series)
In the USA, we have seen that the standard size is the #10 envelopes (4.125" x 9.5") which are engineered to fit perfectly onto a standard 8.5" x 11" letter folded in thirds. Our Envelope Printing service offers these popular business envelopes at affordable prices.
- Window styles: These window envelopes are perfect for invoicing. The window display data, heads up the final consumer of what to expect when open. Many accounting softwares and QuickBooks will recognize this format as well.
- #9 Return Sleeves: This return envelope is slightly smaller than the previous one (3.875" x 8.875") designed with the intention to fit inside the #10. This allows you to include return style functionality, for when expecting a document back or payment so they can mail back effortlessly with an inside pre-addressed piece.
- Security tint protection: This is only available upon request for your custom envelopes, for special situations like medical uses (HIPAA) or legal documents to ensure absolute visible privacy.
Weddings, Galas & Events (A-Series Envelopes)
All wedding events start with a memorable invitation envelope. The A-Series is featured square and elegant, sized specifically for cardstock inner invitations. Our Custom Envelope Printing includes these elegant invitation covers perfect for special occasions.
- A-7 Envelopes (5.25" x 7.25"): By a high margin, this one becomes the king choice for wedding invitations. Fits a 5" x 7" invitation card inside perfectly.
- A-6 Envelopes (4.75" x 6.5"): This size is Ideal for envelope printing "Save the Dates" or 4" x 6" photo cards.
- A-1 Envelopes (3.625" x 5.125"): This smaller size, considered as 'The Petite' size used for RSVP envelopes. Cute, compact, and cost-effective for custom envelope printing.
Catalogs & Contracts (Booklet & Catalog)
When in need of sending a multi-page document like a contract, presentation folder, or product catalog, never fold them, it looks very unprofessional. Rather scale-up to proper dimensions. Our Envelope Printing offers catalog sleeves in various sizes.
- 9x12 sleeves: This is the standard size for a multi-page document presentation that will fit perfectly the popular 8.5" x 11" documents in flat structure. Available in "Catalog" (opens on the short end) or "Booklet" (opens on the long end) styles.
- 10" x 13" Oversized: If the document contains too many pages, having the "Oversized" option will help you in this case. This size works good for bulky folders or thick welcome kits packages that will need extra space and fit in comfortably.
Non-Profit & Fundraising (Remittance)
Mostly used by fundraising, these remittance pieces leverage from a massive flap that can cover almost the entire back of the mailer. This flap becomes the form right away, ready to be filled out by donors. A pre-ready seal will allow to re-close the container and keep all the donors data private.
For these remittance pieces we offer the short and long flaps options depending on what amount of data collection is needed. Our Envelope Printing includes self-seal sleeves for convenient mailing.
Design & File Setup Masterclass
If you are not a pro designer, don't worry. Leverage from our free setup deal, and we will guarantee professional results without you spending a cent. We have the knowledge to build the exact product you need, the correct way and completely free! If you wish to have a more elaborated piece of art, we also have the paid design version.
Anyway, in case you want to build your own, then these are some technical points its good you consider during the build-up of the art.
1. The "Bleed" Area (0.125")
If you wish to have the printed colors all the way to the edge of the paper, please allow an extra 1/8th of an inch (0.125") larger than the actual piece size to be used as a "bleed" area. This is then trimmed off to provide the nice effect like if the paper was printed to the edge. If you are not planning on using bleeding in your design, don't worry about this specific point.
2. CMYK vs. RGB
We use Offset technology to print bulk stationery, so we will require the color format to be CMYK (Cyan Magenta Yellow Black) instead of the popular 'Screens RGB' (Red Green Blue) color setting used mostly by digital and home printers.
3. The "No Ink" Zones
Technical Specifications At A Quick Glance
This is a quick reference table on what to expect from our option selections based on our production line. We prioritize transparency so you know exactly what you are getting.
| Paper Material | 70 lb. Opaque Smooth White (Text Weight) Nicer quality and paper brightness for pop colors and opacity compared to standard 24lb bond. |
| Printer Compatibility | Universal. We have run many tests on home-based printers to make sure they will run perfect for you, every time. |
| Printing Method | Offset Lithography (Flat). For the offset pieces (not digitally printed) we will print flat sheets and then fold and glue accordingly to the specs needed. This is perfect for full bleed. |
| Sealing Mechanism | Standard Gum Seal. We are able to add the gum sealer on the inside of the flap upon request, contact us local for a quote. |
| Resolution Req. | 350 DPI (Dots Per Inch). We recommend any resolution above 300dpi. This will ensure sharp text and images to be printed nicely without distortion. |
| Production Speed | 4-6 Business Days. We would love to make the production time faster, but it's a very delicate and complicated product. Production takes a bit longer than other printing items, taking us from 4-6 business days to produce. Plus a day or 2 for packing and shipping. Production starts after you approve the digital proof. |
3 Simple Steps to Custom Envelopes
We've removed the headache of print file preparation. We make it easy to get high-end custom envelope printing with return address options and full-color branding that pops off the paper.
- Select Your Size: Choose from our extensive list or let's quote you for a custom piece (available options: #10 covers, A7, 9x12 sleeves, etc).
- Send Us Your Data: Use the image uploader form to provide us with all the data, text, logo and images needed for your business mailers or mailing stationery.
- Relax (Free Setup): Our design and pre-press team will manually inspect your files and work on them to set up the bleed, check resolution, and send you a PDF pre-print digital proof for you to approve before proceeding with Envelope Printing.
Download Envelope Pre-Designed Guideline Template File
Envelopes design are among the most complicated products we have on inventory, because they need to be designed and built in specific way to be folded many times into its final form. Remember we can build a custom design free of cost for you, at any time. But if you want to build it yourself, here are a list of all envelope size guideline template files available for you to download and fill in with your art.
We Checked The Online Envelope Print Providers Prices For You
We like it when our customers save up by ordering with us? We keep our direct-to-consumer pricing as affordable as possible and now you can visually compare it for Full Color #10 Envelopes against the biggest and most reputable envelope print companies in the industry.
Envelopes Pricing Examples
Calculator-honest sample totals.
Sample Envelopes calculator total at qty 100 (4x6): $15.00, about 15¢ each before shipping.
Sample Envelopes calculator total at qty 250 (4x6): $25.00, about 10¢ each before shipping.
Sample Envelopes calculator total at qty 500 (4x6): $40.00, about 8¢ each before shipping.
The samples above are for Envelopes calculator defaults. Change options in the order form for your exact job. Shipping is separate and often starts near $14.95 standard after production.
Envelope Printing FAQ
How much does envelope printing cost per quantity?
Buyers asking about Envelopes cost should start in the live calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Change size, material, quantity, and turnaround to see your Envelopes total before checkout. Shipping is separate after production. Use order notes for event dates and install constraints.
What is a standard #10 business envelope size?
Size choice for Envelopes drives both fit and price. Available paths include the sizes listed in the calculator. Lock the trim on the digital proof so nothing clips after press. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Keep critical contacts inside the safe margin on the proof.
Can envelopes be printed in full color on both sides?
For Envelopes on this product page, set specs in the calculator before you upload art. Single-sided saves cost when one face is enough. Double-sided helps when people approach from both directions. Select sides in the calculator so price and art stay correct. Every order gets an emailed digital proof; production starts only after you approve. The live total updates before you add to cart.
Is envelope design free with Free Design Setup?
Artwork for Envelopes can be press-ready or built with Free Design Setup. Free Design Setup is included on qualifying orders when you need layout help instead of a press-ready file. Send logo, copy, and brand colors, or upload a print-ready PDF. Every order gets an emailed digital proof; production starts only after you approve. Approve quickly if your in-hand date is fixed.
Window vs non-window envelopes which do I need?
For Envelopes on this product page, set specs in the calculator before you upload art. Match the job: indoor desk use, outdoor weather, mail rules, or handout volume. Specs here include sizes the sizes listed in the calculator and materials the material options in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Reorders can reuse an approved file when nothing changed.
What paper weight is best for business envelopes?
For Envelopes on this product page, set specs in the calculator before you upload art. Options include the material options in the calculator. Confirm coating and durability needs on the proof. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Ask support if your qty or material path is not listed.
How fast can envelopes be printed and shipped?
Timing for Envelopes splits into production after proof approval, then shipping. Production time and shipping time are separate clocks; shipping starts after print finishes. Standard production is commonly a few business days after proof approval, with rush tiers when qty and specs allow. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Use order notes for event dates and install constraints.
Will I get a proof before envelopes print?
Proof approval is the go/no-go gate before Envelopes hits the press. Every order gets an emailed digital proof; production starts only after you approve. We check type, trim, color, and critical contacts before press. Edits stay free until approval. Free Design Setup is included on qualifying orders when you need layout help instead of a press-ready file. Keep critical contacts inside the safe margin on the proof.
What file format is best for envelope printing?
File prep for Envelopes is what keeps edges and type clean after print. Available paths include the sizes listed in the calculator. Lock the trim on the digital proof so nothing clips after press. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. The live total updates before you add to cart.
Is there a minimum order for custom envelopes?
Quantity tiers for Envelopes start at the calculator minimum. Short runs work for tests; larger breaks usually lower the per-piece rate. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Approve quickly if your in-hand date is fixed. Approve the emailed digital proof before we start production so type, trim, and color are confirmed.
Can return addresses be printed on the flap?
For Envelopes on this product page, set specs in the calculator before you upload art. Specs include sizes the sizes listed in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Every order gets an emailed digital proof; production starts only after you approve. Reorders can reuse an approved file when nothing changed.
Do cheap envelopes look unprofessional for direct mail?
For Envelopes on this product page, set specs in the calculator before you upload art. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Change size, material, quantity, and turnaround to see your Envelopes total before checkout. Shipping is separate after production. Ask support if your qty or material path is not listed.
What is bleed on a printed envelope design?
File prep for Envelopes is what keeps edges and type clean after print. Free Design Setup is included on qualifying orders when you need layout help instead of a press-ready file. Send logo, copy, and brand colors, or upload a print-ready PDF. Every order gets an emailed digital proof; production starts only after you approve. Use order notes for event dates and install constraints.
Can envelopes match my letterhead and business cards?
For Envelopes on this product page, set specs in the calculator before you upload art. Specs include sizes the sizes listed in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Every order gets an emailed digital proof; production starts only after you approve. Keep critical contacts inside the safe margin on the proof.
Are there hidden setup fees for envelope printing?
Artwork for Envelopes can be press-ready or built with Free Design Setup. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Change size, material, quantity, and turnaround to see your Envelopes total before checkout. Shipping is separate after production. The live total updates before you add to cart.
Do you ship envelopes nationwide?
Timing for Envelopes splits into production after proof approval, then shipping. Production time and shipping time are separate clocks; shipping starts after print finishes. Standard production is commonly a few business days after proof approval, with rush tiers when qty and specs allow. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Approve quickly if your in-hand date is fixed.
What is production vs shipping time for envelopes?
Timing for Envelopes splits into production after proof approval, then shipping. Production time and shipping time are separate clocks; shipping starts after print finishes. Standard production is commonly a few business days after proof approval, with rush tiers when qty and specs allow. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Reorders can reuse an approved file when nothing changed.
Can you print security tint on the inside of envelopes?
For Envelopes on this product page, set specs in the calculator before you upload art. Specs include sizes the sizes listed in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Every order gets an emailed digital proof; production starts only after you approve. Ask support if your qty or material path is not listed.
What envelope sizes besides #10 do you offer?
Size choice for Envelopes drives both fit and price. Available paths include the sizes listed in the calculator. Lock the trim on the digital proof so nothing clips after press. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Use order notes for event dates and install constraints.
Can I order matching envelopes with my brochures?
For Envelopes on this product page, set specs in the calculator before you upload art. Specs include sizes the sizes listed in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Every order gets an emailed digital proof; production starts only after you approve. Keep critical contacts inside the safe margin on the proof. This note applies to FAQ #20 on the Envelopes page.
Are self-seal envelopes available with custom printing?
For Envelopes on this product page, set specs in the calculator before you upload art. Specs include sizes the sizes listed in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Every order gets an emailed digital proof; production starts only after you approve. The live total updates before you add to cart.
How do I set up art for a window envelope?
For Envelopes on this product page, set specs in the calculator before you upload art. Specs include sizes the sizes listed in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Every order gets an emailed digital proof; production starts only after you approve. Approve quickly if your in-hand date is fixed.
Can envelopes be mailed through USPS automation?
For Envelopes on this product page, set specs in the calculator before you upload art. Note mount style, stakes, grommets, or mail bundling needs in order comments so we confirm them on the proof. Every order gets an emailed digital proof; production starts only after you approve. Reorders can reuse an approved file when nothing changed.
Can I order short run envelopes for invitations?
For Envelopes on this product page, set specs in the calculator before you upload art. Specs include sizes the sizes listed in the calculator. Sample calculator pricing on this Envelopes page includes $15.00 and $25.00 before shipping on listed default paths. Every order gets an emailed digital proof; production starts only after you approve. Ask support if your qty or material path is not listed. This note applies to FAQ #24 on the Envelopes page.
What is the safe zone for logo placement on envelopes?
For Envelopes on this product page, set specs in the calculator before you upload art. A print-ready PDF is the safest upload. High-resolution JPG or PNG can work for simple art, but type stays sharper in vector PDF. Free Design Setup is included on qualifying orders when you need layout help instead of a press-ready file. Every order gets an emailed digital proof; production starts only after you approve. Use order notes for event dates and install constraints.
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What to expect when you order
Here's what's actually true about every envelope order - not review-widget theater.
We're a small team and don't have thousands of reviews to show off yet - but every review we do have is real.
See our independently verified customer reviews →Envelopes Price List
Select size, paper, sides, and turnaround to see combo pricing for popular quantities.
Sample pricing table below mirrors the live calculator totals for fast, transparent comparison.
| Quantity | Price / Envelope | Total |
|---|
Prices shown reflect printing totals for the selected combination. Taxes may apply where required.
Complete your business mailing kit
Match your envelopes with embossed letterheads for an executive touch, custom shipping labels for outgoing packages, and note cards for handwritten follow-ups that customers keep.
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