Should be able to create a merged letter document and envelope do.

[ErieZoo]

I often use mail merge to create letters. Then I have to create another
document to print envelopes for the letters. I would like to be able to
create one merge document and set up both the letter and the matching
envelope. When I merge the document it should create 2 new documents, one
with the letters and one for the envelopes.

 

[Doug Robbins]

I believe that you are better off with two separate documents that both use
the same data source.

If you set it up as one document, which you can do by selecting the Envelope
that you want to use and click on the Add to document button and then set up
the address fields in the envelope, when you execute the merge, if it's to a
new document, you will get the letters and the envelopes interspersed
throught, i.e. envelope, letter, envelope, letter, envelope, letter, etc.
if you merge direct to the printer, unless your printer can digest the above
being sent to it, it will throw a willy.

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Hope this helps,
Doug Robbins - Word MVP