2025 THYSSE MAIL
OPTIMIZATION GUIDE
Get the most out of your offline
communication budget—with the
right team by your side.
This guide offers a high-level view into mail
and mail process optimization opportunities
we can help you take advantage of.
Thysse’s mail experts are an extension of
your team, adding:
• USPS regulation and postal strategy
• Print production advice
• Creative services
• Tactical marketing support
• Tracking & attribution
• Logistics & channel coordination
• Workflow automation
PROCESS
OPTIMIZATION
“PEMDAS—EXCEPT FOR BETTER ROI.”
The order in which you plan and build a mail campaign
can have a massive impact on both budget and
outcomes. That’s why we recommend bringing
Thysse in at the start, when changes are cheaper and
opportunities are greater.
Our consultative approach is free. Let us show you
where the savings are.
Plan
Define your
audience,
goals, and
messaging.
Engage
Create an
eye-catching
design and
compelling
copy
Mail List
Build or clean
your mailing
list.
Deliver
Print and mail
with precision
(consider
timing,
tracking).
Analyze
Measure
performance—
response
rates, ROI.
Scale
Refine by
segment or
scale based
on results.
OPPORTUNITIES:
SUBSTRATE & EMBELLISHMENT STRATEGY
Choose materials and finishes that qualify
for discounts, elevate your brand, keep you
under weight limits and perform reliably
across variable data, embellishments and
automated equipment.
LIST STRATEGY & DATA SERVICES
Data acquisition, enrichment, segmentation
and delivery modeling—aligned to your
campaign goals.
VARIABLE DATA PRINT (VDP)
Personalization, tracking and
versioning strategies that
drive engagement and unlock
attribution, optimization and ROI.
OMNICHANNEL COORDINATION
Align direct mail with email, digital ads
and website experiences to improve
response rates and automate follow-up.
CREATIVE & PRODUCTION DESIGN SUPPORT
Whether you need a full design team or an
expert gut-check, we’re ready to help refine
your message, and the way it’s delivered.
MAILER TYPE & TEMPLATE SELECTION
USPS-compliant designs that optimize
size, weight and impact.
Optimizing postage is
only part of the picture.
The most successful
campaigns take a broader
view—one that includes
creative strategy, material
selection, data structure,
and omnichannel timing.
“Every mailing is unique. That’s
why we don’t attempt to cover
every scenario—we offer real
experts. The earlier you involve
Thysse in your planning, the more
impact we can make.”
Elizabeth Teubert
Business Development Manager
Thysse
Dec
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sept
Oct
Nov
Dec
Integrated Technology
3% Discount
First Class Letters, Cards and Flats
Marketing Mail Letters and Flats
Nonprofit Marketing Mail Letters and Flats
Tactile, Sensory & Interactive
4% Discount
First Class Letters, Cards and Flats
Marketing Mail Letters and Flats
Nonprofit Marketing Mail Letters and Flats
Continuous Contact
3% Discount
Marketing Mail Letters and Flats
Nonprofit Marketing Mail Letters and Flats
First Class Mail Advertising
3% Discount
First Class Mail Letters, Cards and Flats
Reply Mail IMbA™
3% Discount with Static IMbA™
6% Discount with Serialized IMbA™
First Class Qualified
Business Reply Mail Letters and Cards
Informed Delivery Add-On
1% Discount
Sustainability Add-On
1% Discount
Catalog Insights (NEW)
10% Discount
Marketing Mail Letters and Flats
Marketing Parcels
Nonprofit Marketing Mail Letters and Flats
Growth Over Incentive
30% Credit
First Class Mail
Marketing Mail
Marriage Mail
10% Discount
Saturation Marketing Mail Letters and Flats
(including Every Door Direct Mail®)
Pick your start date:
6 consecutive months
within the calendar year
February 1, 2025 to July 31, 2025
Examples:
Augmented Reality, Mixed Reality,
Virtual Reality, Integration with Voice
Assistance, Video in Print Technology,
Near Field Communication, Mobile
Shopping, Artificial Intelligence.
Examples:
Specialty Inks – Metallic Inks,
Sensory – Coatings such as Soft
Touch, Spot Gloss, Grit, Embossing,
Interactive Elements – Pop Ups, Zip
Strips, Infinite Folds, Trailing Edge
Die Cut, Scratch and Sniff.
April 1, 2025 to December 31, 2025
Mail to the same list a minimum of 2X. Discount is on the 2nd
and following mailings. Mail sequence messaging needs to
carry a single theme and cannot be exactly the same as any
previous mailing.
July 1, 2025 to December 31, 2025
Must have a QBRM permit
October 1, 2025
to June 30, 2026
Ongoing
Create a digital experience tied to your physical
mail via USPS Informed Delivery. Add a ride-
along image and URL that shows up in users’
USPS dashboard or email.
Ongoing
Qualify by using sustainable materials and submitting documentation.
Examples: FSC-certified substrates and recycled paper.
September 1, 2025 to
December 31, 2025
Mail an advertising piece as a
stand alone or included with
a statement/invoice/notice.
To qualify, you must mail more than one million pieces in a year. You’ll earn a postage
credit only for the pieces that go above either one million or what you mailed last year
— whichever number is higher. The credit depends on the type of mail.
Pre-registration required (closed for 2025)
Each piece must include ads from at least four businesses, weigh 2 oz. or less,
and be sent via saturation mail. Discount is applied at the time of mailing.
Examples: HVAC, lawn care, roofing, and pest control companies collaborate
on a shared mailing, lowering postage costs for all participants.
Ongoing – Minimum 10 Mailings per Year
INCENTIVES
ADD-ONS
PROMOTIONS
Applies to bound mail pieces with 12+ pages (stapled, stitched,
or glued). Must include product listings, images, pricing, ordering
info—enough for someone to purchase directly.
2026 Changes
5% Discount
ENROLLMENT BEGINS
November 15
PERIOD
January - December
5% Discount
ENROLLMENT BEGINS
November 15
PERIOD
January 1 - June 30
5% Discount
ENROLLMENT BEGINS
February 15
PERIOD
April 1 - December 31
5% Discount
ENROLLMENT BEGINS
July 15
PERIOD
September 1 - December 31
Discontinued
in 2026
No Change
1% Discount will
continue into 2026
No Change
1% Discount will
continue into 2026
Continues into 2026!
ENROLLMENT BEGINS
August 15, 2025
PERIOD
January 1 - June 30
Give us a call—
let’s talk
pre-registration
for 2026!
No Change
Marriage Mail qualifications
and discounts will continue
through 2026.
POSTAGE
OPTIMIZATION
DOLLARS SAVED = ROI GAINED.
The USPS offers numerous promotions and incentives that can reduce your
postage costs. Thysse tracks them all—and helps you take full advantage.
In addition to promotions, our ability to segment and leverage multiple mailing
methods within a single campaign gives us unmatched efficiency in execution.
Mail Class
Increase Without Discounts
With Discounts
First Class Mail
~8.4%
~7.4%
Marketing Mail
~10.4%
~7.4%
Volume
Old Savings
New Savings
10,000 pcs
$270
$170
20,000 pcs
$540
$340
Entry
Current
New (July 13)
Difference
5-digit Origin
$0.345
$0.372
+$0.027
5-digit DSCF
$0.318
$0.355
+$0.017
2025 Postage Rate Increases
Coming July 13, 2025. These averages assume no promotions or incentives applied:
Drop-Shipping Price Changes
Discounts for drop-shipping to a DSCF (Destination Sectional Center Facility) are decreasing:
Example: Marketing Mail Automation Rates
We'll help you analyze whether the freight-to-drop cost trade-off still delivers ROI.
We’ll compare all methods to ensure your
campaign navigates the USPS ecosystem
as cost-efficiently as possible.
MAIL CLASSES
Let's pick the
most efficient
USPS classification
for your mailing
FIRST CLASS MAIL
MARKETING MAIL
SATURATION MAILINGS
EDDM - EVERY DOOR DIRECT MAIL
Fast, secure delivery
for time-sensitive
or personalized
communications.
Best for invoices,
statements, and
any mail requiring
forwarding or return
services.
Cost-effective option
for bulk advertising
or promotional
campaigns.
Ideal for high-volume
campaigns without
strict delivery
deadlines.
Delivers to nearly
every address in a
geographic area
using simplified
addressing.
Great for reaching
entire neighborhoods
with local offers or
brand awareness
messaging.
A type of Saturation
Mail that targets
routes by ZIP code
without a mailing list.
Perfect for small
businesses looking
to reach nearby
customers without
investing in data.
PRSRT STD
US POSTAGE
PAID
MADISON, WI
PERMIT NO. XXX
NONPROFIT ORG
US POSTAGE
PAID
MADISON, WI
PERMIT NO. XXX
Presorted Marketing Mail offers discounted
rates when you send 200+ pieces sorted by
ZIP Code in advance. Delivery is slower than
First-Class—usually 3 to 10 business days—and
mail isn’t forwarded or returned unless special
services are added.
PRESORTED MAIL
To qualify for nonprofit rates,
your organization must be USPS-
authorized and the return address
must match exactly. We’ll help ensure
your mailpiece meets all design and
postal requirements.
“The earlier we’re
involved, the more value
we can offer.”
Julie Ehrke
Business Development Manager
Thysse
LOCAL USPS DROP
COMINGLED MAIL
DROPSHIPPING
FREIGHT
MAIL METHODS
Let’s choose the
smartest way to
move your mail
Mail is entered at a
nearby USPS facility
for processing.
Best for smaller
campaigns or
when timing isn’t
dependent on
national logistics.
Your mail is
combined with
others to earn deeper
USPS discounts.
Great for maximizing
savings on medium-
to-large mail
volumes.
Mail is transported
closer to its final
destination before
entering the USPS
system.
Reduces transit time
and postage costs
for larger national
campaigns.
Bulk shipments of
mailpieces are moved
via truck or air to
consolidation points
or drop locations.
Necessary for large-
scale campaigns
where logistics and
timing matter most.
VS
Precanceled stamps offer a streamlined way to send
Presorted First-Class and Marketing Mail, particularly
for mailers who prefer a more hand-crafted and
attention grabbing look over permit imprints.
If you choose to use precanceled
stamps with Thysse, we’ll handle
the application and ensure USPS
requirements are met.
PRECANCELED STAMPS
Print on paper stock with minimum
basis weight of 75#
Must meet aspect ratio of 1.3 – 2.5
(width divided by height).
Must be a single or double postcard,
not triple paneled.
Pieces more than 6” long and 4 1/4”
high must be at least .009” thick to
qualify for automation rates.
500 minimum (otherwise mails at letter
rates) at First Class rates qualifies for a
special Postcard Rate.
Cards measuring up to the popular 6”
x 9” postcard size are eligible for First
Class postage. The larger size allows
for more room for your message, white
space, eye-catching CTAs and QR
codes, and all of the other benefits of
mailing in that class.
May qualify for multiple USPS
Promotions, based on piece design.
Some mailers want to attach stickers,
magnets, or other items to their
postcards. Your Thysse Mailing Expert
can assist you with deciding how to
design your postcard.
POSTCARDS
KEY ELEMENTS
FOR EFFECTIVE
POSTCARD DESIGN
Captivating visuals
Use high-quality images or illustrations
that grab attention and relate to your
message.
Concise messaging
Keep the message brief and focused,
aiming for a single clear message.
Color and contrast: Choose colors
that are visually appealing and create
enough contrast for readability.
Personal touch: Consider adding a
personal note or a unique element that
makes your postcard stand out.
Target audience: Ensure the design
resonates with your intended audience.
4 3/4" MAX WIDTH
ADDRESS
CLEAR ZONE
Minimum Font Size: 8pt
We’ll handle
indicia placement—
just keep one of
these areas clear.
5/8" BARCODE CLEAR ZONE
4" MAX HEIGHT
LETTERS
The maximum weight for a First-Class letter is 3.5 oz. and 3 oz. for a booklet.
The maximum weight for a Marketing Mail letter is 4 oz. and 3 oz. for a booklet.
Letter-size mail (not booklets) that weigh between 3 and 3.5 oz. is considered
“Heavy Letter Mail” and must be mailed in an envelope.
In addition, “Heavy Letter Mail” may not include stiff enclosures.
Pieces more than 6” long and 4 1/4” high must be at least .009” thick to qualify
for automation rates.
Must meet aspect ratio of 1.3 – 2.5 (width divided by height).
Cannot be too rigid. Must pass droop test.
Minimum
Minimum
Maximum
Maximum
Length
Length
5"
5"
11 1/2"
11 1/2"
Height
Height
3 1/2"
3 1/2"
6 1/8"
6 1/8"
Thickness
Thickness
.007"
.007"
1/4"
1/4"
5" min.
11 1/2" max.
3 1/2" min.
6 1/8" max.
Item
Envelope Size
Single Card
Narrowfold Card
Broadfold Card
French Fold
A-2
4⅜" x 5¾"
4¼" x 5½"
4¼" x 11"
5½" x 8½"
8½" x 11"
A-6
4¾" x 6½"
4⅝" x 6¼"
4½" x 12½"
6¼" x 9"
9" x 12½"
A-7
5¼" x 7¼"
5⅛" x 7"
5" x 14"
7" x 10"
10" x 14"
A-8
5½" x 8⅛"
5⅜" x 7⅞"
5¼" x 15½"
7¾" x 10½"
10½" x 15½"
#9
37/8" × 87/8"
#10
41/8" × 91/2"
MOST COMMON ENVELOPE SIZES
FLAP TYPES
Following each size are suggested flat size dimensions for the most common insert formats.
ENVELOPE BASICS
Monarch
Commercial
Catalog
Booklet
Item
Envelope Size
Standard Window
Size
Position From
Left
Right
6¼
3½" x 6"
1⅛" x 4½"
¾"
⅝"
6¾
3⅝" x 6½"
1⅛" x 4½"
⅞"
⅝"
3¾" x 6¾"
1⅛" x 4½"
⅞"
⅝"
Monarch
3⅞" x 7½"
1⅛" x 4½"
⅞"
⅝"
7¾
3⅞" x 7½"
1⅛" x 4½"
⅞"
⅝"
8⅝ Check
3⅝" x 8⅝"
1" x 4"
1"
¾"
3⅞" x 8⅞"
1⅛" x 4½"
⅞"
⅝"
10
4⅛" x 9½"
1⅛" x 4½"
⅞"
⅝"
FASTforward® 10
4⅛" x 9½"
1⅛" x 4½"
⅞"
⅝"
11
4½" x 10⅜"
1⅛" x 4½"
⅞"
⅝"
12
4¾" x 11"
1⅛" x 4½"
⅞"
⅝"
14
5" x 11½"
1⅛" x 4½"
⅞"
⅝"
4 WINDOW ESSENTIALS
Size . Position . Patch Material . Shape/Style
Left
Length
Width
Bottom
WINDOW ENVELOPES
Modern window envelopes may be used for a variety of
applications. Standard windows are rectangular with slightly
rounded corners. Special window sizes and styles are also.
INCHES TO DECIMALS
BOOKLETS &
SELF-MAILERS
FOLDED BOOKLET - HORIZONTAL SPINE
Multiple sheets bound at the spine (usually saddle-stitched), folded
along the bottom edge, and sealed at the top and sides for mailing.
Often used for multi-page content like catalogs or program guides.
• Requires three tabs
• Front cover may be up to .25" shorter than inside pages
and rear cover
Minimum
Minimum
Maximum
Maximum
Length
Length
5"
5"
10 1/2"
10 1/2"
Height
Height
3 1/2"
3 1/2"
6"
6"
Weight
Weight
3 oz
3 oz
Thickness
Thickness
.009"
.009"
1/4"
1/4"
BOOKLETS
2-TAB SIDE
PLACEMENT
1 tab on the lead edge
• Within 1" of top
or bottom
1 tab on the trail edge
Same side as lead
(match height for
symmetry)
3-TAB PLACEMENT
2 tabs on the lead edge:
• Top tab:
within 1" of top
• Bottom tab:
0.5" from bottom
1 tab on the trail edge:
• Within 1" of top
WHY IT MATTERS
Tabs will cover part of
your design — keep
key content away from
these areas. We’ll place
the tabs for you, just
share your layout early!
Custom marketing mail is seriously cool — but USPS
rules around flaps and closures can be tricky. Share
your creative ideas with us early so we can make sure
everything meets machinability standards and saves you
money at the same time.
OBLONG SELF-MAILERS
Mailpiece with fold(s) vertical to
length of letter. Final fold must be
on lead edge.
• Mailers up to 1 oz. w/70# text
paper requires two 1" tabs
• Mailers over 1 oz. w/80# text
paper requires two 1 ½" tabs
• There are two placement
options for the tabs
QUARTER-FOLD SELF-MAILERS
Single sheet folded at least two times with the
second fold at a right angle (perpendicular) to the
preceding fold. One sheet of paper quarterfolded
produces four panels.
• Up to 1 oz. on 70# text: 2 tabs
• Over 1 oz. on 80# text: 3 tabs
• 55# newsprint: 3 tabs
THYSSE
STANDARD
• Up to 1 oz. on 70# text: 2 tabs
• Over 1 oz. on 80# text: 2 tabs
• If the address panel is the middle
panel: 2 tab placement options
• If the address panel is the top
panel: 3 tabs are required
BI-FOLD SELF-MAILER
Single sheet folded once in half
forming two panels.
TRI-FOLD SELF-MAILER
Single sheet folded twice forming
three panels.
THYSSE
STANDARD
2-TAB TOP PLACEMENT
Both tabs on the top edge
• Each placed within 1" of the left and right sides
Curious about VDP?
Variable Data Printing lets you personalize each piece—
names, images, offers, and more. Connect with your
Thysse rep to explore what’s possible.
SAME
MAILER,
DIFFERENT
DETAILS
SELF-MAILERS
THYSSE
STANDARD
FLATS
SHAPE &
DIMENSIONS
There is no aspect ratio for flats.
Must be rectangular (for flats, a
square is considered rectangular).
The length of a flat is the longest
dimension.
STRUCTURAL REQUIREMENTS
Must meet flexibility standards (droop test).
Must have uniform thickness that does not cause more
than 1/4” variance.
WEIGHT LIMITS
The maximum weight for a First-Class
flat is 13 oz and for a Marketing Mail
flat is 16 oz.
ELIGIBILITY
Pieces not eligible as a flat are parcels.
PROMOTIONS
May qualify for the Continuous Contact Promotion: The
Continuous Contact Promotion encourages marketing
campaigns with multiple touchpoints to adopt a more
targeted approach that drives customer behavior.
Minimum
Minimum1
Maximum
Maximum
Length
11 1/2"
15 inches
Height
6 1/8"
12 inches
Thickness
1/4"
3/4 inch
1 Flats exceed at least one of these dimensions, based on
landscape orientation, unless the flat is an automation
flat which can have a min length of 6", a min height of 5",
and a min thickness of .009".
12" max.
6 1/8" min.
11 1/2" min.
15" max.
• Pieces not eligible as an EDDM flat are parcels.
• Must be rectangular (for EDDM flats, a square is
considered rectangular).
• Tabs are not required for EDDM mail as this mail
does not go through USPS sorting equipment.
• The maximum weight for a Marketing Mail EDDM
flat is 15.999 oz.
• The maximum weight for a Marketing Mail EDDM
government letter is 4 oz.
• Only agencies of the federal, state, county, or
municipal government may use a Simplified
address on letter-size mailings. See (Postcard/
Letter on previous page for dimensions).
EVERY DOOR DIRECT MAILING (EDDM)
Spine or final fold
edge, if not in
an envelope or
polywrap
The address must be placed
within the top half of the
mailpiece and can appear
on either the front or back—
just not upside down.
Front or Back of
Piece
Front or Back of
Piece
8"
8"
Mr. John Sample
90 Oak St.
Anytown, WA 54321-4002
Mr. John Sample
90 Oak St.
Anytown, WA 54321-4002
Mr. John Sample
90 Oak St.
Anytown, WA 54321-4002
Address can
read right or
left and must be
within top half of
mailpiece
ADDRESSING FLATS
1 EDDM Flats exceed at least one of
these dimensions. Minimum thickness
is .007” and minimum height is 3 1/2”.
This means you can mail a piece that is
a 10 3/4” x 3 1/2” postcard that is .007”.
Minimum1
Maximum
Length
10 1/2"
15"
Height
6 1/8"
12"
Thickness
1/4"
3/4"