Printed letterhead and matching envelopes are the most under-spec'd corporate identity print products in the industry. Most businesses pick whichever 24lb laser-printer paper is cheapest at Staples and call it done. But there's real upside to thoughtful letterhead + envelope pairing — invoices, formal correspondence, and legal documents land with a different weight when they arrive on quality stock from a matching envelope.
Letterhead paper choices
- 24lb bond (~$0.05 per sheet): the universal default. Standard laser / inkjet paper. Fine for everyday correspondence; reads as "office paper."
- 28lb bond (~$0.07 per sheet): noticeable upgrade in hand-feel. Best for professional services (law, accounting, consulting) where impressions matter.
- 32lb premium (~$0.12 per sheet): the "letterhead-as-statement" tier. Substantial paper that arrives feeling considered. Best for executive correspondence and formal legal documents.
- Cotton-content paper (~$0.20+ per sheet): 25% or 100% cotton stock with watermark capability. The classic "white-shoe firm" paper. Best for premium legal, diplomatic, and ceremonial correspondence.
Paper finish
Smooth: standard finish, accepts laser printer toner cleanly. Universal compatibility.
Linen-finish: subtle woven texture. Reads as refined, traditional. Best for professional services.
Laid-finish: visible vertical "ribs" in the paper. Classic, formal. Best for legal correspondence and diplomatic letters.
Recycled / kraft: signals environmental consciousness. Best for sustainability-positioned brands and creative agencies.
Envelope pairing rules
- Match the paper, not the finish. If your letterhead is 32lb smooth white, your envelopes should be 28–32lb smooth white. Mixing weights reads as cheap.
- Closed-back envelopes signal security. Standard #10 envelopes have a single-fold flap. Security envelopes have an interior tint pattern that obscures contents. Use security envelopes for invoices, contracts, and financial documents.
- Self-sealing flaps cost slightly more but feel premium. Pre-glued (lick) envelopes are universal and cheap; peel-and-stick envelopes feel modern; gummed-flap envelopes feel formal.
- Return address printing. Pre-printed return addresses look more considered than rubber-stamped or label-attached versions. Cost: ~$15–25 setup plus ~$0.03 per envelope.
Standard sizes
- #10 envelope (4.125×9.5): the universal business envelope. Holds a tri-folded letter-size sheet.
- #9 envelope (3.875×8.875): standard "reply" envelope, fits inside a #10 for RSVP cards.
- 6×9 envelope: holds a flat half-letter sheet or folded invoice without creasing.
- 9×12 envelope: holds an unfolded letter-size sheet flat. Used for contracts, legal documents, presentation materials.
Letterhead design conventions
- Top third for branding. Logo, organisation name, and key contact info sit in the top 2.5 inches.
- Body text starts at 3 inches. Leave room for the salutation under the masthead.
- Footer for legal compliance. Address, phone, email, and any required regulatory text (bar number, license number, etc.) at the bottom 0.5 inches.
- Margins matter. Body text should have 1-inch margins on all sides for legibility and professional appearance.
Specialty options
Letterhead with foil-stamped letterhead: gold or silver foil for executive correspondence. Adds $50–100 setup plus per-piece cost.
Embossed letterhead: raised dimensional impression of logo or seal. Classic professional services signal.
Watermark paper: built-in transparent watermark visible when held up to light. The ultimate "this is real letterhead" signal.
Practical quantity tip
Order letterhead and envelopes in matched quantities (e.g., 500 sheets + 500 envelopes). Re-running just letterhead because you under-ordered envelopes wastes the setup cost twice. Most businesses go through a full set in 6–18 months depending on volume.