Custom 6×9 Envelopes

Designed To Keep It Neat

We help you create 6×9 envelopes that fit your message and brand — with clean design, precise sizing, and quality printing for a strong first impression.

Material Options

Choose from a range of strong, attractive materials:

• Kraft – Natural and durable
• Cardstock – Heavier for added protection
• Tyvek – Lightweight, tear-resistant
• Recycled paper – Eco-conscious and reliable

Size Accuracy You Can Count On

Each 6×9 envelope is designed to comfortably hold folded 8.5×11” sheets and more — offering a sleek mailing solution without the bulk.

Crisp, Professional Printing

Using digital, offset, or CMYK printing methods, we deliver clear logos, sharp text, and bold visuals with fade-resistant, smudge-free inks.

Functional Add-ons

Enhance your envelope with optional upgrades:

• Peel & seal flaps
• Security tinting
• Custom die-cut windows
• Writable areas or labels
• Perforated tear-off sections

Types of 6×9 Envelopes

We offer versatile formats to fit different needs:

• Booklet envelopes (side-open)
• Catalog envelopes (top-open)
• Self-seal or gummed flap envelopes
• Branded or plain bulk mail envelopes
• Specialty event or invitation styles

Built Around the 3Ps

Every envelope we make supports:

• Presentation – Clean, neat, and aligned with your branding
• Preservation – Keeps contents smooth, unbent, and protected
• Protection – Tear-resistant seams and secure closures

Finish Options for Extra Polish

Refine your 6×9 envelopes with premium finishes:

• Matte or gloss lamination
• Foil stamping (gold, silver, or colored)
• Spot UV for sharp branding
• Embossing or debossing
• Textured paper options

Why Choose Us?

We help you create custom 6×9 envelopes that reflect your purpose and protect your materials. Whether mailing marketing kits or personal invitations, you get:

• Free design and layout assistance
• Fast production and delivery
• Low minimum order quantities
• Consistent quality across batches
• Eco-friendly materials and printing
• Shipping available across the U.S.

Get A Quote

Need compact envelopes that deliver a polished look and secure fit?
To get cost-effective packaging boxes without compromising on quality, you can contact us at (469) 649-8706 or email us sales@customboxeslab.com

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.