Mail Piece Design

Rose FlanaganDirector 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 2.5Side 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• 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 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)

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

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

3.0 maximum weight

Flats Future Address Change

ABC Company123 Main StreetAnytown, US 12345-6789

PRST STDU.S. Postage

PAIDABC Co

Upper 1/3

Bound edge or spine

Parallel or Perpendicular 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

QUESTIONS?

Thank You

www.transcontinentaldirect.com