As versatile as paper can be in the hands of a designer, it still has limitations—specifically, the U.S. Postal Service requirements. These standards, if not observed, can result in a surcharge to the sender because of the added expense of processing and sorting and can run the risk of damage from high-speed post office machinery. That’s an especially costly proposition for any item mailed in large quantity.

Size/Caliper Standards
All mailable matter (individually known by the Postal Service as “mailpieces”) must follow the size standards listed below. The thickness requirement is designed to eliminate flimsy cards and other mail that does not have the stiffness to be processed mechanically.

• All mail pieces .25 inches thick or less must be: rectangular in shape, at least 3.25 inches high, and at least 5 inches long.
•  A mailpiece must be at least .009 (9 pt.) inches thick when it does not exceed 4.25 inches in height and 6 inches in length.
• A mailpiece must be at least .009 (9 pt.) inches thick if it is either greater than 4.25 inches in height or greater than 6 inches in length, or both.

Height to Length Ratio Template
Print out this handy guide and avoid post office surcharges on direct mail. http://www.usps.com/directmail/publications.htm

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Odd-shaped mail pieces
The US Postal Service does have a reasonable rate for odd-shaped mail pieces which they call “Customized MarketMail”. Mailings of 200 or more qualify. Each piece must weigh 3.3 ounces or less and can be rectangular, nonrectangular, or irregular. The minimum dimension is 3-1/2 inches high, 5 inches long, and 0.007 inch thick; the maximum dimension is 12 inches high, 15 inches long, and 3/4 inch thick. Please contact your mailing house or post office for more details before the design is finalized.

Address Orientation
Except for pieces mailed at third-class carrier-route rates, the placement (orientation) of the address on the mailpiece establishes which dimensions are its height and length. The length is the dimension parallel to the address as read; the height is perpendicular to the length.

Because of the orientation of the address, a mailpiece may not meet the minimum-size standards. All pieces that do not meet the minimum-size standards are non-mailable and prohibited from the mail.

Color
Only envelopes and cards with light colors that don’t interfere with automated address-reading should be used. Do not use brilliant colors. Highly glazed paper or paper with an overall design is not acceptable.

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Quality
Envelopes and cards should be constructed of paper strong enough to withstand normal handling. For envelopes intended for automated handling, the Postal Service requires construction from at least 16 lb. paper and recommends using at least a 20-24 lb. basis weight. The strength of the envelope should be able to hold the weight of its contents. A heavier envelope such as 28 lb. and 32 lb. may be better suited for a multi-page mailing, brochures, and booklets.

Caution
The information presented here is for ease of reference. Postal requirements change often and the only way to verify current standards is to contact your local Post Office, mailing house or appropriate government publication. Mohawk assumes no liability or obligation from the use of this information. To order a complete Domestic Mail Manual that is updated quarterly, write to:

Superintendent of Documents
Mail Stop SSOM
Washington, D.C. 20402-9375
Fax: 202-512-2250
Inquiries: 202-512-1800

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For more information:
U.S. Postal Service Website
www.usps.com
Latest information, Postal Bulletin, vendors list, ZIP+4 lookup, Postal forms and publications are available for downloading.

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