This is the beginning of our weekly series on mailing. Check back each week for useful topics which will help you avoid costly mistakes when planning a mailing or designing a mail piece. We’ll cover topics ranging from shapes of mail pieces and sealing methods to the actual messages and which type of mailing list might work best for you.

This first week we’ll jump right into a topic which often causes headaches for people who are new to mailing: folded self-mailers. A folded self-mailer is a style of mail piece where a sheet or multiple sheets are folded together and then wafer-sealed or glued to create a self-contained piece ready for mailing. They are great for advertising since they tend to be more eye-catching than a standard #10 envelope, but there are quite a few regulations to keep in mind when designing them. Orienting or sealing them incorrectly can result in additional postage cost or the piece not being mailable. We’ll keep things basic for now with a single sheet of paper folded and sealed. You’re not limited to these designs, but they’re a great starting point for a first-time mailer; always consult your favorite mailer or the USPS on any piece designs!

The most important thing which must be considered when designing a folded self-mailer is that the final fold must always be on the bottom or right edge of the piece when looking at the address panel. If the final fold is on the bottom and multiple folds are used, the last fold should form the back (non-address) panel to avoid needing extra wafer seals (figure 1). If the folds are done in two directions (quarter-folded), the first fold should form the lead (right) edge and the second fold should form the bottom edge (figure 2).

If the final fold is on the bottom and you’ve followed the rules above, your piece will only need two wafer seals on the top edge within 1” of the left and right edges to be eligible for all machinable and automation discounts (note: these simple standards are for the recommended 70 lb. paper stock; newsprint or other stock may require additional tabs). If the fold is on the lead (right) edge, the tabs will go on the trailing (left) edge within 1” of the top and bottom of the piece (figure 3).

The USPS now requires all tabs to be non-perforated but you still have the option of translucent wax tabs (easier to open) or clear plastic tabs (less noticeable on the piece). The tabs required are 1” diameter for pieces under 1 ounce and 1.5” for pieces over 1 ounce.

These designs should be enough to get a mailing started, so call us when you’re ready!