| Mistakes happen when designing direct mail. Most of them are due to not knowing the postal regulations. Here are ten of the most common design mistakes that are caught by project managers at Thompson Print & Mailing Solutions:
1. No indicia/wrong indicia - Unless you plan to affix stamps or meter postage, a postal indicia will be needed. Print the indicia when printing the mailpiece. Proof the indicia with a postal expert. This can save costly corrections later.
2. Wrong card stock - Postcards and selfmailers have minimum thickness requirements. A 4-1/4 x 6 inch postcard must be printed on 7 point (.007) minimum stock. All oversized cards must be printed on 9 point (.009) minimum stock. Reply cards have the same rules.
3. Hi-gloss paper stock - Many inkjet inks used for addressing will not dry on coated stocks. Check with your mailer before choosing a stock.
4. Nonstandard aspect ratio - The USPS wants rectangular letter mail. To qualify, your piece must fit their "aspect ratio." Divide the height of the mailpiece into the width. Your answer must be between 1.3 and 2.5 inches.
5. Small barcode clear zone - A barcoded lettersize rnailpiece should have a 4 inch wide by 1-1/2 inch deep address area. The barcode must have a 1/8 inch clearance from left and right edge and 5/8 inch from the bottom.
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6. Poor reflectivity - The background behind an address barcode should be white or light colored. Dark colors will interfere with postal scanning equipment.
7. Nonstandard folding - Selfmailers should be folded at the bottom of the address panel. This method requires one tab seal. Mailpieces folded at the top of address panel, short folded or Z-folded will require additional tabs.
8. Improperly sized inserts - Measure all inserts that are to be machine inserted into an envelope. They must be 1/2 inch smaller than the width of envelope and 1/4 inch less in height.
9. Failed tap test - Tap test address cards that are to be inserted into a window envelope. There must be an address clear zone showing through the window even when tapped on the left, right, top and bottom.
10. No Postal Gauge Template - Order a Postal Gauge Template from Thompson Print & Mailing Solutions. It shows how to check for envelope sizes, standard window placement, correct dimensiems for letter mail, barcode location and more. E-mail orders to dt@thompsonprintsolutions.com. It's FREE!
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