Non-Machinable Letters and Cards

If your mailpiece does not meet the machinable standards, you may have to pay the presort rate plus a "non-machinable surcharge." Non-machinable letters require extra steps to bundle the mail before they are placed into trays.

Maximum weight: First-Class Mail: 13 ounces; Standard Mail: less than 16 ounces.

Dimensions: See machinable letters and cards section here.

Examples of a non-machinable letter include:

It has an aspect ratio (length divided by height) of less than 1.3 or more than 2.5 (a square envelope has an aspect ratio of 1, making it nonmachinable).
It is over 4-1/4 inches high and/or 6 inches long and is less than 0.009 inch thick.
It is polybagged, polywrapped, or enclosed in any plastic material.
It has clasps, strings, buttons, or similar closure devices.
It is too rigid.
It has a delivery address parallel to the shorter side of the mailpiece.
It contains items such as pens, pencils, or keys that create an uneven thickness.

Additional restrictions apply to self-mailers and booklets.

First-Class Mail letters (except card-size) 1 ounce or less and Presorted Standard Mail letters 3.3 ounces or less (including card-size) that meet one or more of the non-machinable characteristics above are subject to the applicable non-machinable surcharge: First-Class Mail $0.058, Standard Mail Regular $0.042, or Standard Mail Non-Profit $0.021

Back to Mail Piece Information and Design section | Forward to Automation Letters and Cards