How to Make a Fused Plastic Envelope

Fused plastic is simply "fusing" plastic together with heat. In this case, the plastic is used bags from the store and the heat source is an iron. This project has so many uses. I make envelopes to have custom sizes when I sell items online. You can also make reusable shopping bags, purses, tote bags, and soon, I'm going to make a dog bed base so it won't collect unseemly dog smells. What ever your use is, the process is the same for all.
Don't throw your used plastic bags away! Repurpose them into something useful.

Difficulty: Easy

Instructions

Things You'll Need:

• plastic bags
• scissors
• iron
• waxed paper
• ironing board

1. Cover your ironing board with waxed paper. I cover only half of the board to not waste the paper, then simply iron only in that area. It usually takes two rows to cover.
   
   You will also need a piece of waxed paper to put over your plastic. Only one piece is needed because it can be easily moved around.

2. 

   Stack 8 layers of plastic as smooth as possible on the ironing board. You can use 4 uncut bags, or cut the bags for a larger surface and use 8 bags.
   
   Either way, the goal is to have a piece thick enough to withstand daily wear and will not puncture easily.

3. Put the piece of waxed paper over the plastic and set your iron on the lowest setting.
   Plastic melts quickly and you may have to practice to get a good fuse. You don't want to under melt the plastic because it won't stick together, but if you over melt the plastic, it will develop holes.
   
   constantly move the iron for about 30 seconds on one area, then move to another unfused area.

4. Once one side is fused, flip the piece over and do the same to the other side.

5. If you are making an envelope, cut the plastic into a rectangle and fold in half to make a pocket.

6. You don't have to glue or sew the sides- fused them too!
   
   Put the plastic back on the ironing board and cover only 1/2" of the plastic with waxed paper on one side to fused one "seam", then do the same with 2 other sides.
   
   Flip the plastic over and do the same to the other side so you are left with an envelope that is fully fused on 3 sides.

7. You can now stuff your envelope, fold over the top and fuse the top closed (or just use tape).

Tips & Warnings

• Cut out your pattern after the plastic is fused so you have an exact shape.
• Do not make the iron too hot.
• Make sure all plastic being ironed is covered with wax paper on the top and the bottom