Expandelope® Gusset Envelope

A gusset is an envelope with expandable sides, designed to carry larger bulkier items such as catalogues, books and brochures etc.

They have traditionally been expensive to produce (mostly outside the UK) with long lead times, until now…

Opal Envelopes can produce a more cost effective and user friendly gusset envelope, called an EXPANDELOPE®.

Please take time to watch this promotional video:



The Expandelope® gusset envelope is produced on our existing envelope machinery, on site in Wolverhampton.

Trade envelope overprinters will love our new gusset style, because they are produced flat to make overprinting easy.

The Expandelope® can be produced in stock sizes such as C5, C4, 381x254mm, or in a bespoke size of your choice, with different gusset depths from 10mm to 25mm.

We can manufacture in paper and board weights from 115gsm to 350gsm, and you can add a window if required.

We can print up to 4 colours on inside and outside, and samples are available on request, by calling our sales office on 01902 791212.


Bespoke Envelope Butterfly Craft Kit Expandelope
A 220mm x 220mm expandelope with a 25mm capacity for contents