The United States Postal Service (USPS) has specific requirements for self-mailers to ensure they meet postal regulations for processing and delivery. These requirements help facilitate efficient mail handling and prevent issues during sorting and distribution. Here are some key USPS requirements for self-mailers:

1. Size and Shape:

   • Self-mailers should be rectangular in shape.

   • The minimum size for a self-mailer is 3.5 inches in height and 5 inches in length.

   • The maximum size for a self-mailer is 6.125 inches in height and 10.5 inches in length.

2. Aspect Ratio:

   • The aspect ratio (length divided by height) should be between 1.3 and 2.5.

3. Fold Orientation:

   • The fold should be at the bottom of the mailer, with the address panel and postage on the top half of the mailer.

   • This ensures that the address and postage are visible and machine-readable during processing.

4. Fold Configuration:

   • Self-mailers must be designed to fold in a way that allows the address and postage to be on the same side and face the same direction after folding.

5. Folded Edges and Seams:

   • Folded edges and seams should be secured with appropriate adhesives or fasteners to prevent the mailer from coming apart during processing.

6. Tabbing or Sealing:

   • To ensure that the self-mailer stays closed during processing and distribution, certain sizes and formats may require tabs, glue, or other closures to secure the folded edges. This prevents the mailer from unfolding and jamming processing equipment.

   • The number and placement of tabs depend on the size and weight of the self-mailer.

7. Addressing and Barcoding:

   • The address panel should be located on the top half of the mailer, above the fold.

   • The Intelligent Mail Barcode (IMb) or other USPS-approved barcodes should be printed in the designated area on the mailer to facilitate automated processing.

8. Paper Quality and Weight:

   • The paper used for self-mailers should be sturdy enough to withstand processing without tearing.

   • The weight of the paper should not be less than 70 lb. text weight.

9. Flexibility and Foldability:

   • Self-mailers should be flexible enough to allow for proper machine folding and processing.

It's important to note that self-mailers that do not meet USPS requirements might be subject to additional postage fees or processing delays. Before creating and sending self-mailers, it's advisable to consult the USPS guidelines and work with a knowledgeable printing or mailing professional to ensure that your self-mailer meets all necessary requirements for successful processing and delivery.