Mail Piece Design

By following the mail piece design guidelines provided below, you’ll help ensure prompt delivery of your mailing.

We can also review your mail piece to make sure it meets the relevant guidelines. Please contact us early in the design process—we’ll be happy to help! Contact us at 814-865-7544 for more information.

Folded Mail Pieces (Half- and Tri-Folds)

• Multiple Sheets

  20 lb. bond paper (17” x 22”) minimum = two tabs needed
  
  24 lb. bond paper (17” x 22”) minimum = one tab needed
  
  

• Single Sheets

  28 lb. bond paper (17” x 22”) minimum = one tab needed
  
  20 lb. bond paper (17” x 22”) minimum = two tabs needed
  
  

Thickness

A mail piece must be at least .009” thick to be processed in an automation mailing.

.009” = 67 lb.	Vellum Bristol
125 lb.	Tag
65 lb.	Uncoated Cover
100 lb.	Coated Cover
140 lb.	Index

Closures

• Mail pieces with clasps, strings, buttons, and similar closures cannot be processed in automation mailings.



• Although staples can be used in bindings, they should not be used to seal mail pieces.

Letter-Size Mail Pieces

Letter-size mail pieces that are folded and not enclosed in envelopes must be designed so that the open end is at the top and the folded end is at the bottom. A tab must be used on the open end. (See diagram, below.)

This will ensure that the mailing qualifies for automated mail rates and will also keep the mail piece from tearing during processing.