Industry Trends

Avery Postcards vs. DIY Envelopes: Which Mailing Solution Actually Works for Small Business?

I'm an office administrator for a 30-person company. I order roughly $20,000 annually in labels, cards, and shipping supplies across about 6 vendors. When it comes to getting physical mail out the door—whether it's marketing postcards or oddball packages—I've learned that the "correct" answer depends entirely on your specific situation.

So when I saw questions about the Avery 5689 postcard template and "can I make my own envelope to mail," I realized these are two sides of the same coin. Both are viable. But they serve fundamentally different needs.

What we're actually comparing

Option A: Avery 5689 Postcards – Pre-designed, die-cut, USPS-standard postcards with a specific template. You print at home or office, peel, stick, and mail. No envelope required.

Option B: DIY Envelopes – You make your own envelope from cardstock, printer paper, or even wrapping paper. Then you use a label (like the Avery 5162) for addressing, and you mail it as a letter or flat.

Dimension 1: USPS Compliance and Postage Costs

Avery 5689 Postcards are designed specifically for USPS postcard rates. They're the right dimensions—between 3.5″ × 5″ and 4.25″ × 6″—and they can go for the lower First-Class Mail postcard rate. According to USPS (usps.com), as of January 2025, a postcard costs $0.56 vs. $0.73 for a First-Class letter (1 oz).

DIY envelopes? That's a different story. Unless you're making envelopes that stay within standard letter dimensions (3.5″ × 5″ to 6.125″ × 11.5″), you're paying either letter rate ($0.73) or large envelope rate ($1.50+). And if your homemade envelope is too thick or oddly shaped, it may be returned or charged the package rate.

Honestly, the postcard is cheaper. By about 23%. But the twist: you can't put anything inside a postcard. So if you need to include a brochure, a coupon, or a handwritten note, a postcard won't work. A DIY envelope might be the only option.

Dimension 2: Template Usability and Setup Time

Avery 5689 templates are dead simple. They're available in Microsoft Word, Google Docs, and Canva. You download, type, print, peel, stick. I've used the Avery 5689 for event invites and promotional mailers. My first attempt took about 15 minutes to get the margins right; now it's under 5.

DIY envelopes require more. First, you need a foldable template. There are lots of free ones online, but alignment is tricky. I tried making envelopes for a small run of thank-you notes for a client, and I'll admit: it took me 3 tries to get the fold right. That cost me paper and patience.

But then again, it's hard to beat free. A DIY envelope costs you the paper, the label for addressing (if you want it to look professional), maybe a glue stick. The Avery 5689 postcard has the cardstock built in. If you're just mailing a flat message, it wins on convenience every time.

Dimension 3: Creativity and Customization

DIY envelopes win here, no contest. I've made envelopes from paper bags (though not "paper bag waist shorts"—that's a fashion thing). I've used wallpaper samples, magazine pages, and even thin cardboard. For a niche product—handmade cards, small art prints, promotional thank-yous—a custom envelope makes an impression.

Avery 5689 postcards are beautiful but standard. You can design them in Canva with photos, logos, and custom text, but the final product is still a postcard. It fits in a standard mail stack. People don't say "wow, nice envelope" because there's no envelope.

I get why people go for DIY—creativity matters, especially for small businesses trying to stand out. But that comes at the cost of reliability. I had one DIY envelope returned because it was too thick. Another arrived with a corner torn because the paper wasn't durable enough.

So what should you actually use?

Pick Avery 5689 postcards when:

• You're sending a simple message to a list of recipients (invitations, announcements, promotions)
• You want the lowest postage cost per piece
• Speed and reliability matter—you need them out the door today
• You have 50+ pieces to send (volume makes setup worth it)

Go DIY envelope when:

• You need to include something inside (a card, a sample, a certificate)
• You want a unique, handcrafted impression
• You're mailing a small quantity (under 10 pieces) and don't mind the setup time
• The recipient is someone who appreciates the effort (a VIP client, a collaborator)

And honestly? I use both. For bulk marketing, I'm all-in on the Avery 5689 postcards and a good label template (like the 5162). For personalized notes to key clients or partners, I'll make a custom envelope. It's not about which is better—it's about which fits the message you're sending.

A final caveat: If you're mailing something in a DIY envelope, double-check USPS size and thickness regulations before you seal it. Nothing worse than having 30 returns because they don't fit in the automated sorting machine (Source: USPS Business Mail 101).