Thickness of 0.007 inch to 0.016 inch 

From <https://pe.usps.com/text/qsg300/Q201.htm>

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Postcards are single sheet cards.  (An exception is  double cards, 2nd card must be a business reply card).

A white area of 4" wide by 2 1/4" high in the lower right corner of the card will be sufficient room for the mailing address, barcode and mail permit while allowing for proper clearances.

Delivery address must be  parallel to the longer  dimension of the mailpiece.

First class automated presort postcard postage is often less than the postage for the same card mailed on standard market mail rates, depends on the distribution and density of addresses on the mailing list.

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Letter size Dimensions:

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Thickness of 0.007 inch to 1/4 inch    (and at least .009" thickness if larger than postcard)

From <https://pe.usps.com/text/qsg300/Q201.htm>

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Shape: rectangular. Aspect ratio (length divided by height): 1.3 to 2.5

No clear envelopes, polywrap, clasps, tape, string or staples for sealing (staples are ok in bound edges).

Can be cards, envelopes or folded mailpieces (requires tabs to seal).

The final folded edge must be the bottom of a folded self-mailer unless prepared as an oblong. The final folded edge of an oblong folded self-mailer must be the leading (right) edge.  The max length for folded self mailers is 10 1/2" long.

 

From <https://pe.usps.com/text/dmm300/201.htm>

 

 

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From <https://pe.usps.com/text/qsg300/Q201.htm>

Maximum Weight:

• First-Class Mail Presorted Machinable—3.5 ounces (0.2188 pound).

• First-Class Mail Automation—3.5 ounces (0.2188 pound). 1

• Periodicals Barcoded (Automation)—3.5 ounces (0.2188 pound). 1

• USPS Marketing Mail Automation—3.5 ounces (0.2188 pound). 1

• Enhanced Carrier Route—3.5 ounces (0.2188 pound).

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From <https://pe.usps.com/text/qsg300/Q201a.htm>

 

On a letter-size piece, the recommended address placement is within the optical character reader (OCR) read area, which is a space on the address side of the mailpiece defined by these boundaries (see Exhibit 2.1):

1. Left: 1/2 inch from the left edge of the piece.

2. Right: 1/2 inch from the right edge of the piece.

3. Top: 2-3/4 inches from the bottom edge of the piece.

4. Bottom: 5/8 inch from the bottom edge of the piece.

 

Exhibit 2.1 OCR Read Area

Exhibit 202.2.1

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From <https://pe.usps.com/text/dmm300/202.htm>

A white area of 4" wide by 2 1/4" high in the lower right corner of the card will be sufficient room for the mailing address, barcode and mail permit while allowing for proper clearances.

Delivery address must be  parallel to the longer  dimension of the mailpiece.

 

 

Window Envelope Barcode Placement:

• 0.125 (1/8) inch—minimum clearance between the leftmost and rightmost bars and any printing or window edge.

• 0.028 inch—minimum clearance between Intelligent Mail barcode and top and bottom edges of window.

For envelope window, a clear space must be maintained when insert is moved to its full limits in each direction within envelope (202.5.0).

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From <https://pe.usps.com/text/qsg300/Q201d.htm>

 

 

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Do NOT design a mailpiece with any of the following characteristics.  It will be much more expensive to mail and deliverability will suffer. It may even be prohibited:

Nonmachinable Criteria

A letter-size piece is nonmachinable if it has one or more of the following characteristics (see 601.1.1.2 to determine the length, height, top, and bottom of a mailpiece):

1. Has an aspect ratio (length divided by height) of less than 1.3 or more than 2.5.

2. Is polybagged, polywrapped, enclosed in any plastic material, or has an exterior surface made of a material that is not paper. Windows in envelopes made of paper do not make mailpieces nonmachinable. Attachments allowable under applicable eligibility standards do not make mailpieces nonmachinable.

3. Has clasps, strings, buttons, or similar closure devices.

4. Contains items such as pens, pencils, keys, or coins that cause the thickness of the mailpiece to be uneven; or loose keys or coins or similar objects not affixed to the contents within the mailpiece. Loose items may cause a letter to be nonmailable when mailed in paper envelopes; (see 601.3.3).

5. Is too rigid (does not bend easily when subjected to a transport belt tension of 40 pounds around an 11-inch diameter turn).

6. For pieces more than 4-1/4 inches high or 6 inches long, the thickness is less than 0.009 inch.

7. Has a delivery address parallel to the shorter dimension of the mailpiece.

8. Is a self-mailer that is not prepared according to 201.3.14.

9. Is a booklet that is not prepared according to 201.3.16.

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From <https://pe.usps.com/text/dmm300/101.htm>

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Flat size dimensions:

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* Flats exceed at least one of these dimensions: 

11-1/2 inches width or 6-1/8 inches height or 1/4 inch thickness

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Minimum thickness is 0.009 inch. Maximum thickness is 0.75 inch.

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From <https://pe.usps.com/text/dmm300/201.htm>

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Flats can be rectangular or square shaped. Must be uniform thickness (less than 1/4" variance).

No clasps,  string or staples for sealing (staples are ok in bound edges).

Flats cannot be too rigid or too flexible.

Can be cards, envelopes, magazines, folded mailpieces (no tabs needed).

Clear envelope or polywrapped mailpieces are ok.

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6.2.2 Maximum Weight

[1-21-18] Maximum weight limits are as follows:

1. For First-Class Mail, 13 ounces.

2. For Periodicals, 20 ounces.

3. For USPS Marketing Mail, less than 16 ounces.

4. For Bound Printed Matter, 20 ounces

 

From <https://pe.usps.com/text/dmm300/201.htm>

 

2.2.2 Address Placement on Enveloped or Polywrapped Pieces

The following standards apply to enveloped, polywrapped, or card-style Periodicals (including shrinkwrapped Firm bundles), USPS Marketing Mail, Bound Printed Matter, Media Mail, and Library Mail flats mailed at presorted, automation, or carrier route prices:

1. The “top” of the mailpiece is either of the shorter edges.

2. The entire delivery address must be within the top half of the mailpiece (see Exhibit 2.2.2), except under 2.2.2c or 2.2.2d. Optimal placement is at the top edge (while maintaining the 1/8-inch clearance requirement).

3. If a vertical address will not fit entirely within the top half, the address may cross the midpoint if it is placed within 1 inch of the top edge.

4. If the delivery address is placed on an insert polywrapped with the host piece:

   1. The address must not appear on a component that rotates within the bag.

   2. The address must remain visible throughout the addressed component‘s range of motion.

   3. The insert must be affixed to maintain the address entirely in the top half throughout processing and delivery or, if not affixed, the insert must maintain at least the beginning 0.5 inch of the address in the top half. The “beginning 0.5 inch” means the first half-inch of the recipient, delivery address, and city/state/ZIP Code lines, and not the end of each line.

 

Exhibit 2.2.2 Delivery Address on Enveloped, Polywrapped, and Card-Style Pieces

 

 

 

 

 

 

 

 

 

 

 

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From <https://pe.usps.com/text/dmm300/202.htm>

 

For magazines and folded mailpieces:

The address as read must be within the top half when the bound or folded edge is to the right. It cannot be upside down as read in relation to the top edge.

 

From <https://pe.usps.com/text/qsg300/Q201d.htm>

 

Window Envelope Barcode Placement:

• 0.125 (1/8) inch—minimum clearance between the leftmost and rightmost bars and any printing or window edge.

• 0.028 inch—minimum clearance between Intelligent Mail barcode and top and bottom edges of window.

For envelope window, a clear space must be maintained when insert is moved to its full limits in each direction within envelope (202.5.0).

 

From <https://pe.usps.com/text/qsg300/Q201d.htm>

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