How to Create a DIY Envelope Liner in Silhouette Studio

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I love creating custom envelopes for my handmade cards! More often than not, I make them using one of my favorite tools – the We R Memory Keepers Envelope Punch Board. (Click here to see just how easy it is to use!) When I want to take them one step further, I create a DIY envelope liner as well. It’s pretty easy with the help of Silhouette Studio. Let me show you how!

Getting Started

What you will need:

Let’s start by looking at the chart that comes printed on the Punch Board:

The measurements here will give you the information you need to make both your envelope and the coordinating envelope liner.

  1. Card Size – size of finished card that will fit into the envelope
  2. Paper Size – size of cardstock needed to make the envelope
  3. Score Line – alignment mark for the first score line when making an envelope

If you look specifically at the information for an A-2 size card (4.5 in x 5.5 inch), you’ll see that it requires an 8.125 in square piece of cardstock and the first score line will be at 3.75 in.

Card Size (width x height): 4.5 in x 5.5 in
Paper Size: 8.125 in x 8.125 in
Score Line: 3.75 in

For more specific directions on how to make an envelope using the WRMK Envelope Punch Board, check out this tutorial.

Grab a calculator…

Before we create the envelope liner, we need to do some math.

Note: For the purposes of this tutorial, all calculations are for a liner that is inset approximately 1/8 inch from the edge of the envelope flap. It will also leave a little margin at the bottom of the liner to give you some “wiggle room”. Once you get the hang of making envelope liners, you can adjust the size as desired.

Calculation A
Paper Size – 1st Score Line – 0.7 in =
8.125 in – 3.75 in – 0.7 in =

3.675 in, rounded to

3.7 in

Calculation B
Width of Finished Card + 0.75 in
4.5 in + 0.75 in =

5.25 in

Creating the Cut File

Now let’s create the cut file:

1. Open a new design page in Silhouette Studio. Most envelope liners will fit on a letter-size (8.5 in x 11 in) page.

Screenshot of Silhouette Studio Page Setup Panel

2. Using the Draw a Rectangle Tool, draw a square with the same dimensions as Calculation A.

Screenshot of square drawn in Silhouette Studio

3. Rotate the rectangle 45 degrees by clicking on Object>Rotate>Rotate by 45° (clockwise or counter-clockwise). It will become a diamond shape.

Screenshot of rotated square in Silhouette Studio

4. Here’s where it gets a tiny bit tricky. Refer to the measurements of the finished card size. Draw a rectangle with a width equal to the height of the finished card and height equal to Calculation B.

Screenshot of rectangle in Silhouette Studio

5. Manually align the top of the rectangle with the middle of the diamond.

Screenshot of two aligned shapes in Silhouette Studio

6. Adjust the rectangle until it is the same width as the diamond. (Zoom way in on both images if needed.) Make sure not to adjust the height of the rectangle! Center-align the two shapes by selecting them both and clicking on Object>Align>Align Center.

7. Select both the diamond and the rectangle; right-click and choose Weld.

Screenshot of welded shapes in Silhouette Studio

8. If the welded area isn’t smooth, double-click on the shape to enter point-editing mode and delete any unnecessary points.

9. Cut the design from a piece of coordinating patterned paper. Round the top corner using the Punch Board, if desired. You have just created an envelope liner!


Adhere the liner to the inside of the solid cardstock before you fold it into an envelope shape or slip it into the envelope afterward, whichever you find easier.

Envelope base, envelope liner, and finished 3D flower card
3D Flower Card by Lori Whitlock, Silhouette Design Store ID #39776

Ready to try it for yourself? The process may seem a little bit intimidating at first but once you’ve made a couple of liners, it will get much easier. Keep a master file of your most-used envelope sizes and it will make the process even faster. If you have any questions, just leave me a comment below or visit me over on Facebook. I’ll be glad to help!

And if you’ve found this tutorial helpful, be sure to share the image below to Pinterest.

Pinterest image of 3-D flower card and coordinating envelop

Until next time,

This post may contain affiliate advertising. This means that if you click on a link in the post, I may make a commission based on your purchase. The price you pay for the product or service is not higher, and the commissions I earn help keep Caught by Design online. Thanks for your support!

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