Mail Piece Design Templates

Mail Piece Design Templates


Many mail pieces are folded sheets of paper that form letter-size pieces or newsletters. Folded pieces, or folded self-mailers, can save time and money because you’re not paying for or stuffing envelopes. Folded self-mailers must be sealed or they will be subject to the non-machinable surcharge. We recommend that you use wafer seals or tabs to close the open sides of folded mail pieces. The other option is fugitive glue. If you wish to use fugitive glue instead of tabs call us 619-448-6111 so that we can discuss a design that will work for the post office.

Here’s some good advice on Folding and Tabbing a Mail piece. Put the fold on the bottom (the side below the address) and secure the opening at the top with a piece of tape, fugitive glue, 2 tabs or wafer seals. The minimum size is 3 1/2 x 5 and the maximum size is 6 x 10.5.

Get Template: 8.5 x 11 Tri-fold Self-mailer Template

Get Template: 8.5 x 11 Half-fold Self-mailer Template


Postcards are the most inexpensive way to get an immediate message to customers. When they arrive in the mail, there’s the message — no envelope to open! First-Class Mail postcards are a great value, too. With First-Class Mail postcards, you pay a low price and get all of the benefits, like forwarding and return that come with First-Class Mail. And, if you mail at single-piece First-Class Mail postage, there is no extra work involved — simply drop the postcards in a collection box.

You may think that your mail piece is a “postcard,” because it is a single sheet of paper. But to qualify for mailing at the First-Class Mail postcard price, it must be:

  • Rectangular
  • At least 3-1/2 inches high x 5 inches long x 0.007 inch thick
  • No more than 4-1/4 inches high x 6 inches long x 0.016 inches thick

If your mail piece does not meet the dimensions above, then the Postal Service considers it a letter (and charges letter-size postage). With Standard Mail, there is a little more flexibility — there is no separate (lower) price for postcards, so you don’t have to worry about your postcard being too big — because you’re paying letter prices anyway. But make sure that your postcard is no larger than 6″ x 11-1/2″ x 1/4″ thick. Mail pieces larger than any of those dimensions and you’ll have to pay flats (large envelope) postage prices.

*TIP* If you’re planning to mail a postcard, First-Class Mail gives you the best value for your postage dollars, but you’re limited to 4 1/4″ x 6″ maximum size. At that size, there is no lower postcard price in Standard Mail.

Get Template: 4.25 x 5.5 Postcard Template

Get Template: 4.25 x 6 Postcard Template

Get Template: 5.5 x 8.5 Postcard Template


To be eligible for mailing at the price for letters, a piece must be:

  • Rectangular
  • At least 3-1/2 inches high x 5 inches long x 0.009 inch thick.
  • No more than 6 inches high x 10-1/2 inches long x 1/4 inch thick.

There are special size requirements for mailing letters at automation prices.

First-Class Mail letters that have one or more non-machinable characteristics will pay a non-machinable surcharge. Customers can be unpleasantly surprised that they must pay extra postage when, for example, they mail a square greeting card. The Postal Service charges extra postage because mail pieces that are rigid, square, or unusually shaped, often jam postal equipment and are difficult to process. This costs the Postal Service time and money—and may ruin your mail piece.

Mail Piece Design Tips That Save you Money

The design, size and shape of your mail piece can drastically affect the postage you pay. Here are some tips on designing mail for maximum postage savings.

  • Stay within letter-size. For lower postage rates, keep your mail piece at letter size. Minimum 3.5″ high by 5″ long. Maximum 6.125″ high by 11.5″ long. Mail pieces larger than that fall into the flats category and have a significantly higher postage rate. Folded self-mailers have a special size requirement. Call us to get all the details.
  • Make sure it is thick enough. Mail pieces that are too thin will cost more postage. Keep your piece at least 0.009″ thick and you can save 25 cents or more per piece. Maximum thickness for letter size mail is .25″ and for flat size is .75″.
  • Leave enough addressing space. Allow a large enough open area for the address and barcode. We recommend a 4″ x 2″ clear area.
  •  Address in the right area. Make sure the address and barcode block on letter size mail fits into the USPS OCR read area or you’ll pay additional postage. We can provide you with a template to guide you. Addresses on flat-size pieces must be in the top half of the piece.
  • Address in the right direction. The delivery address on letter size mail must be parallel to the longer dimension of the mail piece or it will be classified as a flat and cost more postage.
  • Proof before you print. Send a mock-up or pdf file to Eye/Comm, before your mail piece is printed. We will gladly assess it for automation compatibility or, if necessary, send it the Postal Service for a ruling. There is no charge for this service and it can save you lots of money and avoid costly delays.

Indicia / Postage Permit Templates

Many mail pieces can be designed with the postage already on them. Permits are used in place of stamps or metering strips, and can be incorporated in the design of your piece, or printed on when we address your mailing.

Standard Mail


Presorted First Class

Full Rate Mail