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Design Questions Answered on MoonlightMail.com


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If you have a design question that you do not see in our list of Frequently Asked Questions - please let us know and we find out the answer for you!

  1. What is a postcard?
  2. What is a letter?
  3. What is a flat or non-letter?
  4. What is the difference between automation and non-automation?
  5. The Post Office said my square postcard is not automation-compatible. Why?
  6. What other standards do I need to watch out for?
  7. How do I decide where to put the mailing address?

What is a postcard?
A postcard (or double postcard*) is a piece that is no less than 3 1/2" x 5" (.007" thick) and no more than 4 1/4" x 6" (.016"thick) in size. Postcard rate is only available with First Class Presort mail. Postcards that are larger 4 1/4" x 6" are sent at letter rates.
*if using a double postcard, one side of the double card must be a proper business reply or courtesy reply card in order to enjoy postcard rates.

What is a letter?

A letter is a piece that is rectangular and is no less than 3 1/2" x 5" and no more than 6 1/8" x 11 1/2" in size.

A letter is always landscape or horizontal shaped. This orientation is VERY important because of its compatibility with the automated postal machines (see information about aspect ratio below).

Thickness requirements:
  no more than 0.25"
  if the size is 4 1/4" x 6" or less, the thickness must be at least 0.007" thick
  if the size is more than 4 1/4" by 6", the thickness must be at least 0.009" thick

What is a flat or non-letter?
A flat (or non-letter) is generally portrait or vertical, however
there are exceptions (ie: 9 x 12 envelopes) where the piece can
be landscape or horizontal in shape. Among other design criteria,
the basics for the shape and size of a flat piece is:
  For height, no more than 12 inches and no less than 5 inches high.
  For length, no more than 15 inches and no less than 6 inches long.
  For thickness, no more than 0.75 inches and no less than 0.009 inch thick.

What is the difference between automation and non-automation?
An automated mailing receives reduced postage rates and faster delivery times. With better technology the post office is able to use machines to process mailings which saves them time and money. If a piece does not qualify for automation, some or all of the mail processing must be done by hand. This will result in higher postage rates and possibly slower delivery time. Even with first class mail, the post office tries to send it automated. It is true you can send a coconut through the mail, but when you are sending business mail, you want it to arrive at it's destination as soon as possible.

The Post Office said my square postcard is not automation-compatible and will incur a non-machineable surcharge. Why?
For a piece to qualify for automation rates, it must meet certain design standards set forth in the Domestic Mail Manual* (DMM). One of these standards is called aspect ratio. This is the dimension of a mailpiece expressed as a ratio of length (the direction parallel to the address) divided by height. For example, a postcard 5-1/2 inches long by 3-1/2 inches high has an aspect ratio of 1.57. An aspect ratio between 1.3 and 2.5 is required for automation compatibility.

What other standards do I need to watch out for?
It is always best to check the DMM or request a copy of the "Designing Letter and Reply Mail" (Publication #25) from your local post office for design standards - but here are a few to keep in mind:

  • Don't use colored or paper with dark fibers (ie: recycled paper)

  • Do use paper that weighs enough to qualify for automated rates - this will not only save money in postage but will also be less likely to be torn in the postal equipment.

  • Don't put words or artwork in the "barcode free zones" (these areas must be clear of extraneous information that might interfere with the barcode readers, see graphic)

  • Do use the correct mail piece orientation (letters should be landscape or horizontal and flats are generally portrait or vertical)

  • Packaging and closures are a very important factor (ie: tabs/wafer seals and plastic bags or covers) - DO NOT use staples! Even with first class mail because it can cause damage to your piece and mailing equipment.

It is ALWAYS a good idea to have your mail piece checked out by your local mail design analyst* - they have the definitive answer on what is good and bad in mail design.

How do I decide where to put the mailing address? Tabs/wafer seals?
On a letter size piece the address MUST be parallel with the longest edge of a piece (see samples below). For a flat, it depends on what mailing equipment the USPS will be using to process your mail, so the orientation may go either way. You should always plan for enough room on your mail piece for the barcode, endorsement line and address information when designing your mail. To learn more on these requirements, download our Direct Mail Checklist.

When designing for automation, the location of the spine or bound edge of a pieces is important. For letters the bound edge should be at the bottom of a piece with the open edges at the top. For flats, bound edges should be on the right of the piece when it is vertical in orientation. The placement of a tab or wafer seal is dependent upon the spine or bound edge of a self-mailer and the weight of the paper. Flats do not require the closure if there are no loose pieces and the spine is on the right side. Letters do require a closure and you can save money if you design your piece to only need one tab or wafer seal. NEVER use a staple to seal the open edges of your mail piece. Always use tape, tabs/wafer seals or spot glue. See the examples below for tab placement.


Double Postcard

Booklet

Self-Mailer with one tab

Self-Mailer with two tabs
On a flat, the bound edge should be at the right of the mailing side. The address information may be at the top, middle or bottom of the mail piece.
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