Publication 25, Designing Letter and Reply Mail

November 2018

Introduction Purpose More Information Postal Groups, Activities, and People Postal Service Specialists Non-USPS Resources 1 Letter-size Basics 1-1 Types of Letter-size Mail 1-2 Physical Standards for Letters 1-3 Address Placement for Letters 2 Machinable and Automation Letters and Cards 2-1 Physical Standards for Machinable and Automation Letters and Cards 2-2 Flexibility Standards for Automation Letters 2-3 Attachments on Letter-size Mailpieces 3 Nonmachinable Letters 3-1 Criteria for Nonmachinable Letters 3-2 Additional Criteria for First-Class Mail Nonmachinable Letters 3-3 Additional Criteria for USPS Marketing Mail Nonmachinable Letters 3-4 Additional Criteria for Periodicals Nonmachinable Letters 3-5 Priority Mail Express and Priority Mail Letters 3-6 Nonmachinable Criteria 3-7 Odd-shaped Items in Paper Envelopes 3-8 Handling, Content, and Extra Service 3-9 Window Envelope 3-10 Green Diamond Border Envelope 4 Booklets 4-1 Definition 4-2 Paper 4-3 Physical Standards for Booklets 4-4 General Booklet Design and Sealing 4-5 Tabs, Tape, and Glue 4-6 Simple Spine Booklets 4-7 Wallet-style Booklets 4-8 Oblong Booklets 4-9 Quarter-folded Booklets 4-10 Folded Self-mailers 5 Letter-size Pieces Containing Discs (CDs or DVDs) 5-1 Basic Standards for Discs in Letter-size Mailpieces 5-2 Disc Size and Placement 5-3 Dimensions and Shape Standards for Automation-compatible Enveloped Letters Containing Disc 5-4 Dimensions and Shape Standards for Automation-compatible (Unenveloped) Disc Carriers 5-5 Unacceptable Characteristics for Automation-compatible Letter-size Pieces with Discs 6 Business Reply Mail 6-1 Overview 6-2 Dimensions 6-3 Ink/Paper Colors and Type Styles

7 Courtesy Reply Mail 7-1 Overview 7-2 Barcodes 7-3 Dimensions 7-4 Ink/Paper Colors and Type Styles 8 Meter and PC Postage Reply Mail 8-1 Overview 8-2 Barcodes 8-3 Dimensions 8-4 Ink/Paper Colors and Type Styles 9 Permit Reply Mail 9-1 Overview 9-2 Using Company Permit Reply Mail Imprint 10 Facing Identification Mark (FIM) 10-1 Description and Purpose 10-2 FIM Standards 10-3 Print Reflectance Difference 10-4 FIM Positives and Barcodes 10-5 Obtaining FIMs, Barcodes, and ZIP Codes 10-6 Importance of Correct Barcodes and FIMs 11 Ink/Paper Information 11-1 Overview 11-2 Ink/Paper Colors and Type Styles 11-3 Paper Quality 11-4 Reflectance 11-5 Address Block Measurements 11-6 Intelligent Mail Barcodes, Delivery Point Barcodes, and FIM Measurements 12 Barcoding Software and Equipment 12-1 CASS and MASS 12-2 PAVE