Dedicated Packaging Manager on Every Order
Dedicated Packaging Manager on Every OrderFree Design Support on Every Custom OrderLow MOQ, Minimums Vary by ProductDedicated Packaging Manager on Every OrderFree Design Support on Every Custom OrderLow MOQ, Minimums Vary by ProductDedicated Packaging Manager on Every OrderFree Design Support on Every Custom OrderLow MOQ, Minimums Vary by ProductDedicated Packaging Manager on Every OrderFree Design Support on Every Custom OrderLow MOQ, Minimums Vary by Product
Home›Corporate Printing›Custom Letterhead Printing

Custom Letterhead Printing.

🏷 Key Specs
📦 500 min. order⏱ 7–10 business days lead time📐 Standard sizes
✨ Finishes
✦ Uncoated✦ Laid Texture✦ Watermark✦ Blind Emboss
▤ Materials
▪ 100gsm Uncoated▪ 120gsm Uncoated▪ Laid Paper▪ Watermarked Stock
☑ Features
✓ Choice of paper stock✓ Full-colour printing✓ Custom sizes✓ Free design help
Starting at
$1.00per unit
🛒 Add to Cart

Final price depends on size, material, finish and quantity. Your packaging manager confirms it before production.

❋ Every Order Includes
Dedicated Packaging ManagerFree Design SupportProof Before ProductionProduction Starts Within 5 Business Hours of ApprovalFree Standard Shipping in the USAAny Size, Made to OrderDedicated Packaging ManagerFree Design SupportProof Before ProductionProduction Starts Within 5 Business Hours of ApprovalFree Standard Shipping in the USAAny Size, Made to Order
★ GET A QUOTEQuick Response

Your custom box, quoted.

01
❋§ 01
1:1
Packaging Manager
02
◷§ 02
7–10 business days
Day Standard Lead
03
✦§ 03
Free
Design Support
04
◇§ 04
A4 210 × 297 mm
Size & Dimensions
05
◉§ 05
USA Wide
Free Delivery
The Atelier Book

The full specification book.

Six chapters. Six colours. Click a tab to turn the page.

Description
Overview

Letterhead Printing

Stationery that has to run through a laser printer and still feel like something.

Letterhead sits between print quality and machine compatibility. Stock has to take toner cleanly, which rules out many of the finishes brands want.

500
Min. order
7–10 business days
Lead time
A4 210 × 297 mm
Dimensions
Custom Letterhead Printing
Uncoated · Laid Texture · Watermark
Crafted to specification

Every detail. Intentional.

It must run through a printer

Which rules out many finishes.

Toner needs an uncoated surface

Coated stock rejects it.

Weight signals the organisation

100gsm to 120gsm typically.

Watermarks read as heritage

Still used deliberately.

Print margins are fixed

Printers cannot reach the edge.

Matched envelope and card

A stationery system, not a sheet.

Custom Letterhead Printing, construction detail
No. 04 · Construction detail
Technical Specs

Built like architecture.

Every order of Custom Letterhead Printing is an engineered build, measured, dieline-cut and hand-wrapped to spec. Below is the standard build sheet.

Defining Constraint
Must run through office printers
Second print pass
Why
Lasers fuse toner with heat
Coatings can blister
Surface
Uncoated
Essentially always
Weight Range
100 – 120gsm
120 the premium choice
Avoid
Lamination, heavy coating, foil
Fuser problems
Texture Options
Laid, watermark
Work with laser
Layout
Body clear, shallow footer
No edge-to-edge printing
MOQ
500 units
Tiered above 1,000

✦ Need a custom spec? Talk to our atelier. Every detail is negotiable.

The Library

Every surface, hand-selected.

What this product is built from, and the surfaces it takes. Below the build sheet sits the full swatch library. Every option applies across our range, and a physical swatch set is available on request.

Material
120gsm Uncoated
The premium standard. Substantial in the hand and comfortable through most office printers.
Most specified
100gsm Uncoated
Economical for high-volume correspondence, and lighter to post.
Volume
Laid Paper
Subtle ribbed texture that reads traditional and is noticed on handling.
Traditional
Watermarked Stock
Mark visible when held to light. Inexpensive at volume and a genuine quality signal.
Premium
Recycled Uncoated
Visible recycled fibre, fully laser-compatible.
Sustainability
Finish
Uncoated
The correct finish. Takes toner reliably and accepts pen ink.
Standard
Laid Texture
Ribbed surface, traditional register.
Traditional
Watermark
Visible against light, produced in the paper rather than printed.
Premium
Blind Emboss
Tactile mark with no ink, positioned away from the print area.
Understated
Matched Stationery
Envelope, compliment slip and continuation sheet on the same stock.
Consistency
Spot Colour
Pantone matching so brand colour holds across reprints.
Brand consistency
01 · Base Stock

Material

The board and paper your box is built from.

◷ FINISH
Art Paper
◷ FINISH
Textured Pearl paper
◷ FINISH
Uncoated Paperboard
◷ FINISH
Linen Textured Paper
◷ FINISH
Laid Paper
◷ FINISH
Vellum Paper
02 · Surface

Finishes

How the outer surface looks, feels, and catches light.

◷ FINISH
Matte Black
Light-absorbing, no glare
PT · MATTE
◷ FINISH
Soft-Touch
Velvet to the fingertip
PT · SOFT
◷ FINISH
Gold Foil
Hot-stamped brilliance
PT · 871 C
◷ FINISH
Matte Lamination
◷ FINISH
Gloss Lamination
◷ FINISH
Soft Touch Lamination
◷ FINISH
Gold Foil
◷ FINISH
Silver Foil
◷ FINISH
Spot UV
◷ FINISH
Holographic Foil
◷ FINISH
Embossing
◷ FINISH
Debossing
◷ FINISH
Anti Scratch Matte
◷ FINISH
Aqueous Coating
◷ FINISH
Full UV Coating
◷ FINISH
Raised Spot UV
◷ FINISH
Drip Off UV
◷ FINISH
Pearl Coating
◷ FINISH
Textured Varnish
◷ FINISH
Sand Touch Coating
◷ FINISH
Glitter UV
◷ FINISH
Rose Gold Foil
◷ FINISH
Rainbow Foil
◷ FINISH
Copper Foil
◷ FINISH
Cold Foil
◷ FINISH
Foil Embossing
◷ FINISH
Blind Embossing
◷ FINISH
Multi Level Embossing
◷ FINISH
Sculpted Embossing
◷ FINISH
Letterpress
◷ FINISH
Edge Painting
◷ FINISH
Edge Gilding
◷ FINISH
Die Cut Detailing
◷ FINISH
Micro Perforation
03 · Extras

Add-ons

Closures, linings, and hardware that complete the build.

◷ FINISH
Belly Band
◷ FINISH
QR Code Card
100gsm Uncoated120gsm UncoatedLaid PaperWatermarked StockUncoatedLaid TextureWatermarkBlind Emboss

✦ Mix and match across all three and we'll build your exact combination.

What We Make

The full kit of capabilities.

✓
Laser-Compatible Stocks
Uncoated surfaces that take toner reliably through a fuser.
✓
Writeable Surface
Accepts pen and ink, which laminated stock does not.
✓
Laid and Watermarked Papers
Texture and quality signals that do not interfere with printing.
✓
Matched Stationery Sets
Letterhead, continuation sheet, compliment slip and envelope on one stock.
✓
Print Area Planning
Layout that leaves the body clear for correspondence.
✓
Blind Emboss
Tactile branding away from the print area.
✓
Recycled Uncoated Stock
Fully laser-compatible.
✓
Spot Colour Matching
Consistent brand colour across reprints.
✗
Lamination or Heavy Coating
Toner does not adhere reliably to coated surfaces and coatings can blister in a fuser. Letterhead has to stay uncoated.
✗
Foil on the Print Area
Foil can cause problems passing through a laser fuser. If you want foil, keep it well away from where letters print.
✓ Laser Compatible✓ Writeable Surface✓ Matched Stationery✓ Watermark Option✓ Custom Print
Measure Twice

Sizing & dieline.

We cut Custom Letterhead Printing to a dieline built around your product instead of pulling a stock size off the shelf. Send us the length, width and height of the item (or the item itself) and we return a measured dieline, free, before you commit to anything.

Size Range
A4 210 × 297 mm
Custom dieline
Stock Dimensions
A4 8.27 × 11.69 in · US Letter 8.5 × 11 in
L × W × H
Dieline File
Free with every quote
AI / PDF / DXF
Artwork Setup
Free structural design
Included
Tolerance
±1.5 mm on finished size
Industry standard
How to measure
01
Measure the product

Length, width and height of the item itself, at its widest points. Measure the product, not the box you happen to use today.

02
Add clearance

Allow 2–4 mm on each axis for a snug fit, and more if you are adding foam, a pillow insert or tissue.

03
Give us the order

We quote as Length × Width × Height. Tell us whether you are working in millimetres or inches and we match it.

Available constructions
A4US LetterContinuation SheetCompliment SlipMatched Set

✦ Not sure of your size? Send us the product and we measure it and build the dieline.

What It Costs

Pricing & minimums.

We price Custom Letterhead Printing per specification rather than from a fixed list, because the same build in two different finishes can land at very different numbers. Below is what actually moves the price, so you can shape the spec before you request a quote.

Minimum Order
500 units
Lower MOQ on request
Maximum Run
100,000 units
Larger volumes quoted
Standard Lead Time
7–10 business days
After artwork approval
Rush Lead Time
5–7 business days
Surcharge applies
Pricing Model
Quote-based, per specification
USD
Design & Dieline
Free, included in every quote
No setup fee
Sampling
Physical sample before bulk
Credited on order
What moves the price
Quantity

The single biggest lever. Unit cost falls sharply as volume rises, because setup and tooling spread across more pieces.

Material and thickness

Board weight and stock choice change both the raw material cost and the shipping weight of the finished run.

Finishing

Foil, spot UV, embossing and soft-touch each add a pass on press. One or two lift the box; five compound the cost.

Print coverage

Full-bleed print inside and out costs more than a one-sided design on natural stock.

Inserts and hardware

Foam, moulded pulp, velvet pillows, magnets and ribbon are priced per piece on top of the box itself.

Timeline

Standard production is the base rate. Rush moves you up the production queue and carries a surcharge.

✦ Quotes returned within 24 hours.

Frequently Asked Questions

Questions, answered.

Everything you need to know about Custom Letterhead Printing.

Because the sheet gets a second print pass in your office laser printer, and toner will not fuse properly to a coated surface. The fuser heats the paper to bond the toner, and a coating can blister or let the toner flake off in the tray.

Uncoated stock takes toner cleanly and also accepts pen ink for a signature. That is why nearly every letterhead we make is uncoated, regardless of how the brand's other print is finished.

Not across the print area, no. Foil and laminate both cause fuser problems in office printers, so we keep them off letterhead entirely rather than risk a jam or a blistered sheet.

If you want something tactile, a blind emboss positioned away from the body of the letter works, and a watermark produced in the paper itself reads as quality without any surface build-up at all.

100gsm to 120gsm, with 120gsm as the choice most organisations settle on. It feels substantial in the hand and still runs comfortably through most office printers without curling or misfeeding.

100gsm suits high-volume correspondence and is lighter to post. Going heavier than 120gsm starts to push the limits of ordinary printer trays, so we'd talk you through it first.

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