This doesn't covers every printing issue, but here are a few of the issues we see most often. If you have a question that isn't answered here, though, please feel free t give us a call—1.866.862.4141. We can ensure that your mailpiece meets Post Office requirements before it's sent to the printer.
Mailpiece Size
Postcards must be 3 1/2" X 5" to 4 1/4" X 6" and .007+ inches in thickness. Cards over 4 1/4" X 6" must be .009+ inches in thickness. If these minimums are not met, the Post Office needs to manually process them which will result in substantially higher postage costs to you.
Letter-Size mail has the least expensive postge cost. Letter-size is 3 1/2" X 5" to 6 1/8" X 11 1/2", less than 1/4" thick and rectangular in shape—a square mail piece will result in a "nonmailable surcharge". The aspect ratio (length divided by height) must be between 1.3 and 2.5. For example, 4" X 5" is unacceptable (5 divided by 4 equals 1.25). Pieces smaller than 3 1/2" X 5" cannot be mailed.
Envelopes & Inserts
Using proper envelopes will also keep postage costs down. Envelopes with deep V flaps or ragged edge flaps (typically found on invitation envelopes) interfer with the ability to machine process your mail. Keep these guidelines in mind when you purchase envelopes.
- Flaps no deeper than 2 5/16"
- inserts at least 1/2" less than the width and 1/8" to 1/4" less than the height of the envelope.
- The number of inserts may also affect your dimensions. Please let us know the entire make-up of your mailing when you call.
- Window envelope inserts should not shift inside the envelope causing obstruction of view of the address.
Self Mailers
These are mail pieces designed to be mailed without an envelope—for example, a folded sheet that is addressed. To qualify for the less expensive automation-based postal rates, tabbing to keep the mailer shut may be required by the Post Office. Only one tab is required when the solid edge is positioned at the bottom of the mailer (as you are looking at the address panel). Two or more tabs are required if the solid edge is positioned at the top of the mailer. Booklets, however, must have two tabs as closures, each within 1" of either edge. The spine should be at the bottom and should be the longest edge of the piece.
When printing self-mailers or postcards, it is generally best to preprint the permit indicia on your mail piece at the same time that your piece is printed. Below are examples with the correct verbage as required by the Postal Service.
Permit Indicias for presorted standard mailings—please contact us if mailing First Class or using an envelope. The U.S. Postal Service no longer accepts the wording "Bulk Mail" within the indicia.
Profit 
Non-Profit
Addressing
Always leave a 4" wide X 1 1/2" high area for addressing. This area must also be a minimum of 5/8" from the bottom of your mailing. White or pastel backgrounds work best for machine readability and are required for the lower automation rates. A white address label will be required when using dark colored mailers. The mailpiece address should always run parallel to the longest edge of the mailpiece.
NCOA
Over 40 million Americanns change their address each year. NCOA provides mailers with a secure and convenient manes of correcting outdated customer adresses while protecting customer information. The process reduces the number of undeliverable mail pieces, resulting in less waste and lower postage costs. Mail delivery is no better than the address on the mail piece. Contact us to update your customer list today—1.888.862.4141
