A redesign of the classic Envelope Punch Board for We R Makers, shrinking the tool to roughly half its original footprint while combining a scoring guide, notch punch, and corner punch into a single body that makes custom envelopes and liners in nearly any size.
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Challenge
(01)
Rethinking the Original
The original punch board worked well but took up a large amount of bench space for a task most crafters do occasionally, and its sizing chart limited users to preset dimensions, so the goal was to reduce the footprint without cutting capability and to make custom sizing something the user could look up rather than guess at.
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Solution
(02)
Consolidate and Calculate
I consolidated the score guide, notch punch, and rounded corner punch into one compact housing with a lift tab and angled alignment edge that positions paper for each of the four sides, then paired the tool with an online Envelope Punch Up Calculator, reachable by a QR code printed on the board, that returns exact paper size, liner size, and start number for any card dimension.
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Conclusion
(03)
The Result
The patent-pending tool produces clean folds, notched flaps, and rounded corners in a footprint that fits a working desk, and moving the sizing math off the printed chart and into a calculator opened up box envelopes, liners, and non-standard card sizes without adding parts to the tool itself.
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