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