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Mailpiece Design
Rose Flanagan
Director of Mailing Services
Transcontinental Direct
If you can make it fit into a standard off the shelf automation #10 envelope then you’re just fine.
If not . . . .
6 1/8"max.
11 1/2" max.
3 1/2" min.
5" min.
Thickness: .009” min. - .25” max.
Physical Characteristics– Letter Size Mail
Postcards 7 point
Maximum letter weight 3.3 ounces (3.5 for automation rate pieces)
Pieces over 3.0 ounces must be in an envelope
Aspect Ratio – Letter Mail
Length Divided by Height = 1.3 to 2.5Side parallel with the address is the length.
Meets AspectRatio
OutsideAspectRatio
5 / 4 = 1.25 6 / 4 = 1.5
4"
6"
Standard Mail pieces out of Aspect Ratio pay non-machinable rates up to 3.3 ounces. Over Standard Mail pieces out of Aspect Ratio pay non-machinable rates up to 3.3 ounces. Over 3.3 pay Not-Flat Machinable rates.3.3 pay Not-Flat Machinable rates.
5"
4"
Physical Characteristics -Machinable Letter Size Mail
• Flexibility - must be able to bend easily• Uniform thickness - No odd shaped items• No shrink-wrap, polywrap, and other plastic-like coverings• Envelopes must have straight edges, rectangular in shape• Card type mail pieces may have finished corners that do
not exceed a radius of 0.125 inch• Not more than 3.3 ounces (3.5 if automated)
• Pieces over 3.0 ounces must be in an envelope• ECRLOT letters must meet automation requirements
Letter Size Tab Automation Requirement
Folded Self Mailer
Folded Self Mailer
One Tab- fold at the bottom - Single sheet- 28 lb basis weight paper- Multiple sheets- 24 lb basis weight paper
Two Tabs- fold at the top or bottom -Single or multiple sheets- 20 lb basis weight-Over 7 inches
tabs must startwithin 1 inchfrom right and left side-tabs on sidealso an option
NOTE: The USPS is currently testing self mailers, oversized postcards and slim jims for automation compatibility
Tabbing Booklets
Two Tabs- top or sideBound edge on bottomFront & back cover-minimum basis weight 20 lb
Booklet Style-multiple sheets
with a spine or bound fold
Tab on top 1” from left and right edge
Or tab left and right sides 1” from top
Or tab left and right sides 1” from top
NOTE: The USPS is currently testing self mailers, oversized postcards and slim jims for automation compatibility
Minimum 8-point font Lines & characters in the address must not
touch or overlap Each element on the address line may be
separated by no more than 3 blank spaces
USPS proposal published in October 10 Federal Register. Comments were closed on December 10, 2007. Final rules not published.
Proposed Letter Size Address Requirements
Physical Characteristics – Automation Flat Size Mail
12 “max.
5” min.
6” min.
15” max.Length
Height
3/4” thick max.
Physical Characteristics – Flat Size Mail
More than 11-1/2 inches long, or more than 6-1/8 inches high, or more than 1/4 inch thick
Not more than 15 inches long, or more than 12 inches high, or more than 3/4 inch thick Length defined as the longest dimension. Height defined as the dimension
perpendicular to the length. Automation Flats:
Minimum size 5” x 6” Maximum size 12” x 15” (including Car-Rt)
Maximum thickness 3/4” Rectangular Uniform thickness – no more than 1/4” variance Non-paper contents smaller than the outside package may not shift more than
2” if shifting results in non-uniform thickness or contents bursting out of envelope
Must be flexible Boxes and box-like pieces are not flats
Flexibility Characteristics – Machinable Flat Size Mail
How to test your flat piece for Machinability (DMM 301.1.4): Place the piece with the length parallel to the edge of a flat
surface & extend the piece halfway off the surface. Press down on the piece at a point 1” from the outer edge, in
the center of the piece’s length, exerting “steady” pressure. The piece is not flexible if it cannot bend at least 1” vertically
without being damaged. The piece is flexible if it can bend at least 1” vertically without
being damaged and it does not contain a rigid insert. No further testing is necessary.
Continue testing if it can bend at least 1” vertically without being damaged and it contains a rigid insert.
Maximum Deflection for Automation – Flat Size Mail
For pieces 10” or longer: Place the piece with the length perpendicular to the edge of a flat
surface and extend the piece 5” off the surface. Turn the piece around and repeat the process.
The piece is automation-compatible if it does not droop more than 4” vertically.
For pieces less than 10” long: Place the piece with the length perpendicular to the edge of a flat
surface and extend the piece 1/2 of its length off the surface. Turn the piece around and repeat the process.
The piece is automation-compatible if it does not droop more than 1” less than the extended length. (example 8” piece extended 4” off cannot droop more than 3”)
For pieces with bound or folded edges perform the tests by placing the bound or final folded edge perpendicular to the edge of the flat surface.
Rigid pieces: At least 4” high but not more than 12” high At least 4” long but not more than 15 3/4” long At least .009 thick but not more than 1 1/4” thick
Pieces less than 5” long must be over 1/4” thick Flexible pieces at least 4” high but not more than 12” high if:
Over 15” long but not more than 15 ¾” long Over 3/4” thick but not more than 1/4” thick
UFSM 1000 (over 3/4” thick, or over 15” length or under 5” x 6”) Non-Machinable letters weighing over 3.3 ounces Must be barcoded (unless in 5 digit containers) or pay an $0.05
surcharge Postnet or Code 128 if less than 6 oz; Code 128 if more than 6 oz
Physical Characteristics– NFM (Not-Flat Machinable)
Flats Sequencing SystemFSS
Dulles FSS Installed & Running Test Decks
Dulles FSS Installed & Running Test Decks
Flats Proposed Address Position
Standardized Address Placement for Flats published in the Federal Register October 10, 2007 All flat mail must be output from the flats sequencing machine with the
bound edges aligned (unless enveloped or polybagged). Address orientation must be right reading in relation to the top edge
Top edge: Enveloped or Polywrapped pieces is defined at either of the shorter edges Bound or folded pieces it is the upper edge when the bound or final folded edge is vertical
and on the right
Addresses must be a minimum of 8 point type; additionally lines or characters must not touch or overlap
Address elements may be separated by no more than 3 blank spaces Automation rated mail must contain 11-digit barcode
Comments closed December 10, 2007. Final rules not published.
Flats Proposed Address Placement
Parcels
Mailpieces that are neither letters or flats 3 processing categories
Machinable Irregular Outside
Machinable Parcels
Machinable Parcels
Not less than 6 inches long, 3 inches high, 1/4 inch thick, and 6 ounces in weight, unless qualifying for a Lightweight Parcel
Not more than 34 inches long, or 17 inches high, or 17 inches thick, or 35 pounds in weight. For books or other printed matter, the maximum weight is 25 pounds
Lightweight Parcels
A machinable parcel may weigh less than 6 ounces (but not less than 3.5 ounces) if it meets all of the following conditions:
The mailpiece is rectangular and able to maintain its integrity during mail processing
The mailpiece bears a parcel barcode according to spec Mailpieces weighing at least 3.5 ounces but less than 5 ounces must be a
paperboard or fiberboard box within the following dimensions: At least 1.5 inches thick and no more than 3 inches thick. At least 6 inches long and no more than 7 inches long. At least 3.5 inches high and no more than 5 inches high.
Mailpieces weighing at least 5 ounces but less than 6 ounces must be within the following dimensions: More than 3/4 inch thick and no more than 6 inches thick. At least 6 inches long and no more than 12 inches long. At least 3-1/2 inches high and no more than 9 inches high.
Irregular & Outside Parcels
Irregular (ref DMM 401.1.6) Rolls & tubes up to 26” long Parcels not meeting machinable parcel specifications
Outside (ref DMM 401.1.7) Exceeds any of the maximum dimensions for a machinable
parcel Examples include liquids; paints; rolls & tubes longer than 26”;
harmful matter, etc.
Return Address
Required on all mail pieces with stamp or company permit imprints
Required on the delivery address side of a mailpiece when using ancillary services (i.e. Address Change Service, etc.)
QUESTIONS?
Thank You