Mail Piece Design Rose Flanagan Director of Mailing Services

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 remain at 7 point Maximum letter weight 3.3 ounces (3.5 for automation rate pieces) (3.0 for booklet self mailers)

Aspect Ratio – Letter Mail Length Divided by Height = 1.3 to 2.5 Side parallel with the address is the length. Meets Aspect Ratio Outside Aspect Ratio 5 / 4 = / 4 = 1.5 4" 6" Standard Mail pieces out of Aspect Ratio pay non-machinable rates up to 3.3 ounces. Over 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 Must have straight edges, rectangular in shape Not more than 3.3 ounces (3.5 if automated) ECRLOT letters must meet automation requirements

Physical Characteristics – Flat Size Mail 12 “ max. 5” min. 6” min. 15” max. Length Height 3/4” thick max.

Physical Characteristics – Flat Size Mail Minimum size AFSM 100 standards –Minimum size 5” x 6” –Maximum size 12” x 15” (including Car-Rt) Length defined as the longest dimension. Height defined as the dimension perpendicular to the length. 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” 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 ): –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)

Letter Size Tab Automation Requirement 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 start within 1 inch from right and left side- tabs on side also an option

Tabbing Booklets Two Tabs- top or side Bound edge on bottom Front & 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 3.0 maximum weight

Flats Future Address Change ABC Company 123 Main Street Anytown, US PRST STD U.S. Postage PAID ABC Co Upper 1/3 Bound edge or spine Parallel or Perpendicula r to the bound edge

Standardized Address Placement for Flats as recommended by MTAC: –All flat mail must be output from the flats sequencing machine with the bound edges aligned (unless enveloped or polybagged). –With bound edges aligned to the right, all addresses appear in the top third of the mail piece (top half of smaller pieces such as 5 ½” x 8 ½”) –Addresses either perpendicular or parallel to the bound edge, final fold or longest dimension (envelopes) –Address orientation requirements to be made by the Postal Service. May require address right reading (upside down not allowed) Expected publication of requirements in Federal Register this summer with a possible 1 year implementation time line. Flats Future Address Placement

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