Custom Envelope Printing and Conversion Services

mailing.com manufactures custom envelopes in the same facility where your mail is printed and assembled. Production turnaround is measured in days, and there is no third-party markup built into the cost.

Remove Dependencies From Your Mail Production

Eliminate Third-Party Sourcing

Your envelopes are manufactured in the same facility where your mail is printed and assembled, which removes supplier lead times, shipping delays, and the coordination overhead of managing an outside envelope vendor.

Keep Your Production on Track

Envelope runs are timed to your print production calendar so inventory is available when jobs are ready. There is no waiting on a shipment or adjusting your schedule around a supplier’s timeline.

Design to Your Specifications

Custom sizes, window placements, security features, and branded printing are all handled in-house, so you are not limited to what is available off the shelf or what an outside supplier can turn around in time.

Custom Envelope Conversion

At mailing.com, we are committed to helping you create the perfect envelopes for your direct mail campaign. If you have a preferred type of paper, we are happy to convert it into the envelope style of your choice.

Available Envelope Sizes

#10s
#9s
6×9
A10
A9
A8
A7
A6
A2
Full flap 6.75 remit
Full flap #9 remit

All sizes are available in window or non-window.

In-House Production

Instead of sourcing envelopes from an outside supplier and coordinating delivery timelines, your envelopes are manufactured in the same facility where your mail is printed, assembled, and prepared for USPS.

Custom Sizes and Formats

Envelopes are manufactured to your exact size, flap style, and format specifications for programs that require something beyond standard off-the-shelf options.

Muliple Window Configurations

Single and multi-window envelopes are built to align with your document layouts so recipient addresses, account numbers, and return addresses display correctly without manual intervention.

Branded Envelopes

Custom printing, color matching, and logo placement are applied during the conversion process so your envelopes match your brand standards and arrive looking professional.

Security Features

Tinted interiors, tamper-evident closures, and security patterns are available for programs that handle sensitive or confidential correspondence.

Production-Matched Inventory

Envelope runs are scheduled and sized to match your print production volumes, so inventory is available when your jobs are ready and you are not warehousing excess stock.

No Third-Party Markup

Because your envelopes are manufactured in-house, there is no outside supplier adding margin to every order. You pay for production, not for a middleman between your envelopes and your mail operation.

Custom Die Cutting

Custom die cutting enables us to create unique and customized envelopes that perfectly match your specific needs and branding. Our state-of-the-art cutting tools and machinery can create envelopes in a variety of shapes, sizes, and styles that are not possible with traditional envelope production methods. This level of customization helps you stand out your competitors and create unique brand experiences.

How it Works

Your envelope conversion is coordinated with your print and mail production, so everything comes together on schedule without outside dependencies.

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Step 1

Specifications and Format

We document your envelope requirements including size, window placement, paper stock, branding, and any security features. Our team confirms that specs align with your document layouts and postal requirements.

Step 2

Proofing and Approval

A sample envelope is produced and submitted for your review. We confirm window alignment, branding, print quality, and format before the full run begins.

Step 3

Manufacturing

Envelopes are produced in our facility on a schedule that aligns with your print production timeline so inventory is ready when your jobs hit the floor.

Step 4

Production Integration

Finished envelopes move directly into your mail assembly and inserting workflow with no outside shipping, no third-party coordination, and no gaps in the chain of custody.

Security and Compliance at Every Stage of Production

Every step of your mail program runs through a controlled, certified environment. Data is encrypted in transit, stored in access-controlled systems, and processed under role-based permissions. Printed materials follow a documented chain of custody until they reach USPS and every stage is logged, monitored, and tied to named accountability.

Security and Compliance Standards

Scale with Ease

Scalable capacity supports growth without changing security or compliance posture.

Redundant Production

Mirrored production sites ensure continuity and uninterrupted delivery during peak demand.

Operational Controls

Sensitive customer, financial, and health data is protected through standard operating procedures.

Frequently Asked Questions

What is envelope conversion?

Envelope conversion is the process of manufacturing custom envelopes from flat paper stock. This includes cutting, folding, gluing, window patching, and printing to produce envelopes built to your exact specifications.

What types of custom envelopes can mailing.com produce?

We manufacture envelopes in custom sizes, window configurations, flap styles, and paper stocks. We also support branded printing, security tinting, and tamper-evident closures for programs that handle sensitive correspondence.

Why does in-house envelope conversion matter?

When envelopes are manufactured in the same facility where your mail is printed and assembled, there are no outside supplier lead times, no shipping delays, and no gaps in the chain of custody. Your production schedule stays on track and your envelopes are built to match your specific document layouts.

Can mailing.com match my brand standards on custom envelopes?

Yes. Custom color matching, logo placement, and print specifications are applied during the conversion process so your envelopes are consistent with your brand across every mailing.

How does envelope conversion connect to other mailing.com services?

Envelope conversion is integrated into your broader production workflow. Finished envelopes move directly into print assembly and mailing without leaving our facility, all managed by the same team that handles your data, printing, and postal coordination.

How long does custom envelope production take?

Most custom envelope runs are completed within days. Outside envelope manufacturers typically run one to three weeks out before the order ships, and that lead time sits between your production schedule and your mail date. Because mailing.com manufactures envelopes in-house, turnaround is significantly shorter and production is scheduled directly against your print calendar. For recurring programs, envelope inventory is timed so stock is always available when jobs are ready.

Let’s Talk About Your Mail Program

Whether you are looking to move an existing program or set up something new, we would like to hear about what you need. Tell us about your mail volume, your document types, and your compliance requirements, and we will put together a plan.