Custom Forms & Letterheads
Direct mail letterhead in mail printing combines professional branding with efficient production and mailing processes to delivery impactful campaigns. Clients benefit from enhanced credibility, higher open rates, personalization, and strong ROI. CMKY is ideal for vibrant, marketing -focused Letters, while black suits formal or budget-conscious mailings. Standard Stocks (e.g. 24lb. white wove, 80lb. linen) and sizes (8.5" x 11" letterhead, #10 envelopes). Letter-only formats work informational mailings, while letter/reply formats with " perf reply" components (e.g. personalized reply cards) are popular for action-driven campaigns, especially in fundraising and sales.
Envelopes
For cost-effective direct mail envelopes that adhere to U.S. Postal Service guidelines, select standard sizes like #10 (4.125" x 9.5") or 6" x 9" to ensure machinability and qualify for Firs-Class or Marketing Mail automation rates, minimizing postage costs. Envelopes must USPS requirements for aspect ratio (1.3 to 2.5), thickness (0.007" to 0.75"), and weight (up to 3.3 oz for First-Class letters), using lightweight, durable paper to balance quantity and affordability. Avoid non-machinable features like non-standard flaps, odd shapes, or adhesive glues on flaps, as these require processing by a mail house significantly increasing costs.
Postcards
For cost-effective direct mail postcards that adhere to U.S Postal Service guidelines, opt for standard sizes like 4.25" x 5.5" or 4" x 6", which quality for First-Class Mail postcard rates and minimize postage costs. Ensure the postcard meets USPS thickness requirements (0.007" to 0.016" thick) and use durable, high-quality cardstock to withstand mailing without compromising print clarity. Design with clear, bold visuals and concise messaging to addressing and postage as per USPS layout rules.
Buckslips
Adding a color or monochrome buckslip to your direct mail package brings flair, enhances engagement. CMYK buckslips deliver vibrant, attention-grabbing designs for sales and promotions, while black offer elegant simplicity on colored or textured stock for formal or budget campaigns. Standard sizes like 3.5" x 8.5" or 4"x 9" fit into a #10 envelope and meet USPS guidelines. Standard stocks (70lb. uncoated 80lb. glossy) balance cost and durability, while specialty stocks (recycled, linen, colored) add premium touch. We ensure efficient printing and mailing for high-ROI campaigns.
Brochures
When printing brochures for mailing, adherence to U.S Postal Service (USPS) guidelines is critical to ensure cost-effective and efficient delivery. USPS Standards specify size, weight and format requirements for various classes, such as First-Class or Marketing Mail. For brochures, key considerations within machinable limits (e.g., 3.5" x 5" minimum, 6.125" x 111 x 5" maximum for letters) and ensuring proper folding and sealing to withstand automated processing. Aspect ration (length divided by height) must fall between 1.3" and 2.5" for automation discounts. Additionally, brochures must include a clear address panel, barcode space, and proper postage or indicia placement.
Booklets
When printing booklets for mailing compliance with the U.S. Postal Service (USPS) guidelines is essential to ensure efficient processing and cost-effective delivery. USPS standards for booklets, typically classified as flats or letters depending on size, require specific dimensions (e.g. 3.5" x 5" minimum, 11.5" x 6.125" maximum for letters; up to 12" x 15" for flats). and an aspect ratio of 1.3 to 2.5 for automation compatibility. Booklets must be securely bound (e.g. stapled or stitched). with a spine on the bottom or right edge and sealed with tabs or glue to prevent opening during transit. A clear address panel, barcode area, and proper postage or indicia placement are also required.
Newsletters
For cost-effective newsletters sent via direct mail that comply with U.S. Postal Service guidelines, choose standard flat sizes like 8.5" x 11" or 11" x 17" folded to 8.5" x 5.5", which quality for First-Class or Marketing Mail rates, optimizing postage savings. Ensure the newsletters meets USPS requirements for thickness (0.009" to 0.25" for flats) and weight (up to 3.3 oz for First Class Mal) using lightweight, durable paper stock to balance quality and cost.
Labels
Printing vibrant promotional labels for your campaigns can elevate your offers and sales with eye-catching appeal. CMYK full-color labels deliver bold, vivid designs, showcasing logos, discounts, or product images that grab attention, while black labels offer a sleek, cost-effective option for minimalist or elegant promotions. Standard stock like glossy or matter white adhesive provide durability and affordability, fitting most campaigns. For a special touch, specialty stocks - such as clear adhesive for seamless look, metallic foil for luxury, or textured linen for sophistication-add tactile and visual flair, making your mail stand out. These choices enhance brand perception, boost open rates, and drive responses, ensuring your direct mail campaign leaves a lasting impression.
Response Cards
Direct mail response cards in letter packages, adhering to USPS guidelines (e.g. 3.5" x 5" minimum, 3.5 oz), are cost effective, with printing and mailing. They drive strong response rates for non-profits though personalization. Standard stocks like 14pt glossy or matte cardstock balance cost and durability, while specialty stocks (e.g. recycled, linen add flair. Common sizes (4" x 6", 5.5" x 8.5") ensure compliance and fit #10 envelopes, the most common envelopes used providers like AMi direct, offer end-to-end solutions for efficient, high ROI campaigns.
Flyers
Flyers work best when tailored to the audience and integrated into multi-channel campaign (e.g. pairing with mail follow-up). Overuse of generic flyers or lack of personalization can reduce effectiveness. Testing designs and tracking responses are key to optimizing ROI.
Calendars
Printing promotional calendars for direct mail requires careful planning to ensure high-quality output, cost efficiency, and compliance with mailing requirements. Packaging use 9" x 12" envelopes or rigid mailers for wall/desk calendars as an example. The vest time to print and mail calendars is October-December for January use to align with recipients' needs and USPS Capacity.
Business Cards
Incorporating business cards into direct mail campaigns is a strategic best practice, as it provides a tangible, professional touchpoint that recipients can retain, increasing brand recall and engagement. A standard business card, sized at 3.5" x 2", is compact yet versatile, fitting easily into envelopes or as an insert alongside brochures or letters. Including a business card a direct mail piece-such as a personalized letter or promotional flyer-works effectively because it serves as a convenient reference for contact information, encourages follow-up actions, and reinforces brand identity through consistent design.











