How much can a Tyvek expansion envelope hold?

Choose gussets from approximately 1 to 4 inches to match your insert thickness. We can help estimate capacity based on page count and paper stock.

Tyvek is highly water- and tear-resistant (not fully waterproof like plastic) and protects far better than paper mailers.

Can you print full color on Tyvek?

Yes—CMYK and Pantone spot colors both print cleanly on Tyvek. We run prepress checks for placement and coverage.

What closure is best for heavy inserts?

Peel-and-Seal / Zip-Stick provides a strong, fast seal. For extra-heavy loads, ask about reinforced flaps and seam options.

Do you offer custom sizes or special runs?

Yes. We can produce non-standard sizes, capacities, and print layouts for large or specialized projects.

> Tyvek > Expansion

Tyvek® Expansion Envelopes (Gusseted)

Protect bulky mailings with lightweight, tear-resistant, water-resistant Tyvek®. Our gusseted expansion envelopes load easily, keep corners crisp, and arrive looking professional—without the weight and bulk of traditional mailers. Order plain or custom-printed in small runs or bulk.

Are you mailing 3-4 envelopes to the same office? Consolidate and use one expandable Tyvek envelopes to save time and postage. View available sizes, get bulk quantity pricing.

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If you need a product that is not listed on our site, call 612.867.2121 or email our Sales Department at doug@easyenvelopes.com.

Why Choose Tyvek® Expansion Envelopes?

Gusseted capacity: Side or bottom gussets expand to fit catalogs, binders, manuals, and folders.
Durable yet light: Tyvek® resists tears, punctures, and moisture while reducing postage versus heavy mailers.
Clean, bright white: Smooth surface prints logos and text with sharp detail.
Secure closures: Peel-&-Seal / Zip-Stick® options help seal fast and clean—no moisture required.
Custom printing: 1-color spot to full-color CMYK, with prepress checks for alignment and placement.
Bulk-friendly: Carton quantities and volume pricing available; ask about scheduled releases.

Popular Sizes & Capacities

Common flats and gussets shown below; custom sizes/capacities available on request.

Flat Size (W × H)	Gusset (Expansion)	Typical Use
10" × 13"	1"–2"	Thick reports, manuals, small binders
12" × 15.5"	1.5"–3"	Catalogs, book sets, document folders
13" × 18"	2"–4"	Large packets, oversized materials

Specs & Options

Feature	Details
Material	DuPont Tyvek® (spun-bond olefin), bright white
Gusset Style	Side and/or bottom gusset; reinforced seams for capacity
Closures	Peel-&-Seal / Zip-Stick® or equivalent; gummed by request
Basis Weight	14 or 18# Tyvek® typical (varies by size/spec)
Printing	Plain, 1-color spot, or full-color CMYK; face/back/flap imprint areas
Carton Qty	250 per carton

Best Uses

Catalogs, lookbooks, annual reports, and multi-piece kits
Training manuals, binders, and engineering documents
Presentation folders and product literature packs
Mailings exposed to rain, humidity, or rough handling

FAQs

How much can a Tyvek® expansion envelope hold?: Choose gussets from ~1" to 4" to match your insert thickness. We can also help estimate capacity based on page count and stock.
Is Tyvek® waterproof?: Tyvek® is highly water- and tear-resistant (not fully waterproof like plastic) and protects far better than paper mailers.
Can you print full color on Tyvek®?: Yes—CMYK and Pantone spot colors both print cleanly. We run prepress checks for placement and coverage.
What closure is best for heavy inserts?: Peel-&-Seal / Zip-Stick® provides a strong, fast seal. For extra-heavy loads, ask about reinforced flaps and seam options.
Do you offer custom sizes or special runs?: Absolutely. We can produce non-standard sizes, capacities, and print layouts for large or specialized projects.

Get Pricing & Samples

Need 250 or 10,000+? We offer the best price and quality. Call 612.867.2121 or email doug@easyenvelopes.com.