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Designing Your Mailpiece  
Create a practical but effective mailpiece.
Ensure that adequate margins for manufacturing tolerances are built into the design. Of particular concern are mailpieces designed such that addressing and barcode placement must be exact in order to meet the Domestic Mail Manual (DMM®); or final piece size is exactly on the dividing line between rate categories (letter to flat, flat to parcel). Pieces designed to these specifications may produce a wide variety of results when run on MERLIN™ program. Consider the variations that are introduced during the multiple production phases involved in producing a mailpiece:

The variations that occur during production include:

Offset printing registration
Trim, bindery, and finishing tolerances
Image placement variations
MERLIN image processing variations

Related Services & Links
Domestic Mail Manual
Quick Service Guide – Designing Letters and Postcards for Automated Processing
Quick Service Guide – Tabs and Wafer Seals
Quick Service Guide – Designing Flats for Automated Processing
Mailpiece Design Analyst Lookup