How to Design for Direct Mail
"Why won't the Post Office accept my Self Mailer that way?"
There are times that a design element causes a mailing to go at a higher rate of postage or be refused for mailing completely. This can be frustrating as well as costly. One of our core services is to review your design to verify that it meets USPS mailing specifications and requirements. Our mailing experts have over 30 years of experience working with the Post Office and will assist you in avoiding the pitfalls of mail piece design.
Here are some simplified design guidelines for several standard mail piece types.
USPS Design Requirements by Mail Category:
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Postcards
Size: 3.5" x 5" - 4.25" x 6"
Paper stock: minimum of 0.009" thick and less than 0.016" to meet USPS Automation Require
Aspect Ratio: between 1.3 - 2.5 (length divided by height)
Address Block: 2.5" x 4" clear address block area (no images). The block needs to be a minimum 0.5" inches from either edge and 0.625" inches from bottom edge. The block can be no higher from the bottom of the mailer than 3.5" inches.
Jumbo Postcards
Size: 4.375" x 6.25" - 6.125" x 11"
Paper stock: minimum of 0.009" thickness to meet USPS Automation Requirements
Aspect Ratio: between 1.3 - 2.5 (length divided by height)
Address Block: 2.5" x 4" clear address block area (no images). The block needs to be a minimum 0.5" inches from either edge and 0.625" inches from bottom edge. The top edge of the block can be no higher from the bottom of the card than 4.0" inches.
Folded Self-Mailers (FSM's)
Size: 3.5" x 5" - 6" x 10.5"
Paper stock: Minimum of 70# Uncoated Text or 80lb Coated Text
Aspect Ratio: between 1.3 - 2.5 (length divided by height)
Address Block: 2.5" x 4" clear address block area (no images). The block needs to be a minimum 0.5" inches from either edge and 0.625" inches from bottom edge. The top edge of the block can be no higher from the bottom of the card than 4.0" inches.
Folding Specifications (Mailing requirements are very strict for Folding): For horizontal folds: the final fold must be at the bottom of the mail panel. This can be an 8.5" x 11" half folded, an 11" x 17" quarter folded to 8.5" x 5.5", a 10.5" x 35.5" roll folded to 6" x 10.5" and on and on. For vertical folds: the final fold is to the right of the mail panel. This can be a 5.5" x 17" folded to 8.5" x 5.5" and so forth.
Tabbing: up to 1 ounce mailer requires two 1" tabs, mailers over 1 ounce require two 1.5" tabs On a horizontal fold you will have two tabs above the mail panel or one to the right and one to the left. On a vertical fold you will have one tab above mail panel and one or two to the left. Fugitive gluing: use a continuous glue line of 1/8 inch wide or glue spots of 3/8 inch diameter, 3 to 4 spots or elongated glue lines 1/8 inch wide, 3 to 4 lines.
Poly bag/envelope: If you use a poly bag or envelope your mail will have to go at flat postage rates. Unless, you are using specially produced Clear Envelopes that are USPS Approved. Please Contact us for more information about these options.
Letter Rate Booklets
Size: 5" x 7" - 6" x 10.5"
Paper stock: Minimum weight for the cover is 60# to 80# text depending on the design.
Aspect Ratio: between 1.3 - 2.5 (length divided by height)
Address Block: 2.5" x 4" clear address block area (no images). The block needs to be a minimum 0.5" inches from either edge and 0.625" inches from bottom edge. The top edge of the block can be no higher from the bottom of the card than 4.0" inches.
Binding Location: You may either bind to the right of the mail panel or at the bottom of the mail panel.
Tabbing: 3 tabs are required with a minimum 1 ½ inch diameter and they may not be perforated. If binding is below mail panel, then two tabs are required to the right of the mail panel and 1 tab to the left. If the binding is to the right of the mail panel, then two tabs are required above the mail panel and one tab to the left.
Poly bag/envelope: If you use a poly bag or envelope your mail will have to go at flat postage rates. Unless, you are using specially produced Clear Envelopes that are USPS Approved. Please Contact us for more information about these options.
Flats
Size: Width over 6.125" or length over 11.5". Up to .75" Thick.
Paper stock: minimum of 0.009" thickness to meet USPS Automation Requirements
Address Block: Flats are required to have address blocks in the upper half of the short edge. For instance, with an 8.5" x 11" mailer the address block will need to be above 5.5" from the top. You will need to use a 4" x 2.5" clear address block area (no images). On books, this is either in the top half of the back cover or the lower half of the front cover addressed upside down or parallel to the spine of the book.
Folding or Binding: The folded or bound edge must be to the right of the mail panel. This is for self-mailers or books, if you are using a poly bag or envelope this is not necessary.
Poly bagging: If you use a poly bag the maximum extra space you can have inside the bag from the edge of the piece to the edge of the bag is 0.5".
Conclusion
Your best bet is to design your mailer and then send a pdf to us in order to have us find any problems with the design. We can help to make sure you are automation compliant and save on postage. As you are going through the process, do not let it stop your creativity. It is the unique and creative pieces that get the recipients attention and increase your ROI.
