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Direct Mail
Letters and Flat Cards
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1. Machinable Letters and Flat Cards
(Processed through automated equipment at USPS)
Letters and Flat Cards must meet specific length, height and thickness characteristics to be processed on Postal Service equipment. Mailpieces must be rectangular in shape and display an accurate address. Length is the dimension parallel to the address.
9 PT. PAPER OFFERINGS
NEENAH offers several cover weights that meet the 9pt minimum thickness for flat cards over 4.25” x 6.0“.
(Insert diagram below) Note: This diagram illustrates the various dimensions and respective basis weights required for Flat Cards to be deemed “machinable” and eligible for automation.
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2. "Non-Machinable Letters and Flat Cards
(Processed by hand at USPS)
Mailpieces with an aspect ratio (length divided by height) of less than 1:3 or more than 2:5 are also considered non-machinable and subject to non-machinable surcharges. Pieces with the address parallel to the height are also considered non-machinable.
Folded Self-Mailers
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1. "Machinable" Folded Self-Mailers
(Processed through automated equipment at USPS)
These mailers must meet specific size, weight and thickness requirements in order to be processed by Postal Service equipment. Take into consideration both size and weight when designing your mailpiece.
The Postal Service has developed a quick reference document covering common foldings, acceptable closures and basis weight information. This document is available at: ribbs.usps.gov
70 TEXT OFFERINGS
70 lb. Text is the minimum paper basis weight required for folded self-mailers. This weight allows the Post Office to effectively process mail through their automated systems without damage to the mail piece. NEENAH offers a myriad of papers in a variety of colors and finishes to meet this need.
Note: All Folded Self-Mailers must be opened at the top with the final fold at the bottom. These mailers require at least 2 adhesive tabs applied to the top, lead or trail edge to be secured for automation purposes.
Note: The illustration at right shows the minimum and maximum mailing panel dimensions of a folded self-mailer.
Download Clear Zone Templates
for Folded Self-Mailers -
2. "Non-Machinable" Folded Self-Mailers
(Processed by hand at USPS)
Mailpieces below the minimum or exceeding the maximum sizes listed in the above diagram are deemed non-machinable. An 11” x 17” Tri-fold is an example of a non-machinable folded self-mailer and is subject to increased postage.
Additional Resources
- USPS National Customer Support Center: ribbs.usps.gov
- USPS Postal Explorer: pe.usps.com
- USPS Mailpiece Design Analyst (MDA): call 855-593-6093 or email mda@usps.gov
- MailProDigital: mailprodigital.com
This information is intended to simplify the USPS regulations for your direct mail projects. While we made every attempt to be accurate with the information we shared, only the USPS can supply information that is guaranteed accurate. Always consult with your Post Office representative to make sure you are compliant with the rules and regulations.