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We’ve been referencing the changes in Folded Self-Mailer (FSM) standards that the USPS will put into effect January 5, 2013 for about a year now but as that date gets closer I wanted to take one more look at what I believe are the most important changes that you should be aware of:

1)      Change in Size: The maximum standards for letter-size mail are 6 1/8” high, 11 ½” long and 3.3 oz. The FSM maximums arebeing reduced to 6” high, 10 ½” long and 3 oz. In and of itself, this is a big change, but one that is easy to adjust to by changing up print layout sizes if you favor the larger format. Where I also see some potential for concern is mostly in the change from 6 1/8 to 6 – especially for self-mailers with lots of pages/folds. The extra 1/8” on a 6×9 folded self-mailer allowed for issues with layout, folding or cutting that may have made a 6” piece slightly taller, even if just on a percentage of the mailing. It will be interesting to see if this issue comes up and how the USPS handles it. My recommendation – plan for error and make your final print height slightly less than 6”.

2)      Mail Panel Location for Tri-Folds: This change surprised me and will present some challenges when designing a tri-fold mailer. What the regulation states is that not only can the final fold not be on the top, but the mail panel has to be in the center panel. This is a big change if you typically plan on having two panels consecutive in the design on the mail side. Take this as an opportunity to get creative with your design and maybe find ways to make the mail panel flow with the rest of the page!

3)      Elimination of Final Top Fold: This change makes sense when you think about mail processing equipment - mail that is completely closed on the bottom will travel better through the system than mail that has the potential to open or nest into other mail because the bottom is open. This should be an easy adjustment to make but don’t get caught with this design element after the fact!

4)      Paper Requirements: This will have an effect on those of you who like to send out single sheets either tri-folded or bi-folded. The minimum paper weight for any FSM under 1 ounce will now be 70lb and for pieces over 1 ounce the minimum will be 80 lb. What this means is printing your flyer on copy paper will not work and just meeting the minimum 9pt thickness requirement when folded may not be enough. My recommendation – when in doubt, go with the thicker paper stock.

5)      Elimination of Single Tabs: This is more of a cost issue than anything else. All FSMs will require at least two tabs (and they can’t be perfed tabs), depending on the design of the mailpiece. If you are concerned about tab placement, talk to your Streamworks rep to find out where they will be placed on your mailpiece.

I strongly suggest that to avoid any complications with the new requirements that you either 1) let Streamworks manage your print projects. After all, who better to print mail than the mail experts? Or, 2) have your Streamworks contact review your print proofs before going on press. Once the mail is printed, you are likely stuck with the costly upcharges from the USPS for designs that don’t meet their standards.