Design tools
USPS mailpiece layout guides, drawn to scale
Pick a piece and a real size. Every drawing is rendered at true proportion from the dimensions you choose - the address block, Intelligent Mail barcode (a real, encoded 65-bar IMb at USPS geometry), OCR read area, barcode clear zone, tabs and fold edges are placed by the rules in DMM 201, 202 and 204. Numbered callouts key to the rule table under the drawing. For layout planning; final designs go to your BMEU or a Mailpiece Design Analyst before production.
The barcode
Intelligent Mail barcode, at USPS geometry
The IMb on every drawing above is a real encoding (USPS-B-3200): 65 bars in four states - full, ascender, descender, tracker - carrying a 20-digit tracking code and an 11-digit routing code. Bars are drawn at the nominal spec: 22 bars per inch, 0.020 in wide, 0.145 in full-bar height, 0.050 in tracker. Plavidian generates and prints the IMb on your pieces from your Mailer ID and serial range; you leave the space, we fill it.
Reference
USPS DMM reference by mailpiece type
Postcard (DMM 201 §1.2, 202 §2.1 and §5.0)
Card price: 3½ x 5 in minimum; retail maximum 4¼ x 6 x 0.016 in; commercial (presorted / automation) cards up to 6 x 9 in from July 12, 2026, with the thickness USPS sets for the larger card. Cards follow the letter rules for the OCR read area and barcode clear zone. On a card divided vertically into a message portion and an address portion, the address portion must be at least 2⅛ in wide.
Letter (DMM 201 §1.1, 202 §2.1 and §5.0)
3½ x 5 in to 6⅛ x 11½ in, up to ¼ in thick, aspect ratio 1.3-2.5. OCR read area: ½ in from left and right, from ⅝ in to 2¾ in above the bottom edge. Barcode clear zone: right 4¾ in x bottom ⅝ in, blank except for the barcode. IMb in the address block (rightmost bar ≥ ½ in from right, top of bars < 4 in from bottom, address bottom line ≥ ⅝ in from bottom) or in the clear zone (bars ⅓₀⁽ to ½ in from bottom, leftmost bar 3½-4¼ in from right).
Flat (DMM 201 §4.0, 202 §2.2 and §5.2)
Larger than a letter in any dimension, up to 12 x 15 x ¾ in. Enveloped, polywrapped or unbound: "top" is either shorter edge and the entire address must be within the top half; parallel or perpendicular to the top edge, never upside down, ≥ ⅛ in from any edge. Bound or folded (catalogs, booklets, folded 11 x 17): "top" is the upper edge when the bound or final-folded edge is vertical on the right - so the address goes on the back cover with the spine to its right. Automation IMb anywhere on the address side ≥ ⅛ in from any edge.
Folded self-mailer (DMM 201 §3.14)
3½-6 in high, 5-10½ in long, up to 12 panels. Final folded edge is the bottom of the piece (unless prepared as an oblong). Address on the outside panel, not across a fold. Bi-fold and tri-fold to 3 oz: two nonperforated tabs on the top edge, one within 1 in of the leading (right) edge and one within 1 in of the trailing (left) edge; 1 in tabs to 1 oz, 1½ in over 1 oz. Oblong pieces: one tab centered on the top edge and one centered on the trailing edge.
Booklet - simple spine (DMM 201 §3.16.5)
Spine is the bottom edge. Three tabs of 1½ in: one on the leading (right) edge and one on the trailing (left) edge, each within 1 in of the top; one on the lower leading edge ½ in from the bottom. Cover 50 lb minimum to 9 in long, 60 lb over 9 in (basic design). Address on the back cover; the letter OCR read area and barcode clear zone apply.
Booklet - oblong (DMM 201 §3.16.7)
Spine on the leading (shorter, right-hand) edge as the address side is read. Three tabs of 1½ in: two on the top edge and one centered on the trailing (left) edge. Cover 60 lb to 9 in long, 70 lb over 9 in; maximum 3 oz.
Booklet - wallet (DMM 201 §3.16.6)
Spine at the bottom, 4 in high, 5.2-8 in long, maximum 2½ oz. To 2 oz: 1½ in tabs on the leading and trailing edges 1¼ in from the bottom. Over 2 oz: 2 in tabs ¾ in from the bottom. ± ⅛ in vertical tolerance.
Tabs (DMM 201 §3.11)
Nonperforated, minimum 1 in. Tight to the edge, no more than ₁₀₆ in overhang. Tabs that fall in the barcode clear zone must meet background reflectance; vinyl tabs and cellophane tape are not acceptable in the clear zone. Glue spots may replace tabs within ¾ in of the open edges on some designs.
Downloads
Downloadable template PDFs
One PDF per piece type at its default size, generated from the same drawings as the guide above - true-size pages you can print and lay a comp on. Pick another size above and use "Download this drawing" for that exact size.
Postcard 6 x 4¼ in - address side
Download PDF
Letter - #10 envelope 9½ x 4⅛ in
Download PDF
Oversized card 6 x 11 in at the letter price
Download PDF
Flat - unbound, portrait 9 x 12 in
Download PDF
Flat - unbound, landscape 12 x 9 in
Download PDF
Flat - bound or folded 8½ x 11 in (spine right)
Download PDF
Folded self-mailer - bi-fold 8½ x 5½ in
Download PDF
Folded self-mailer - tri-fold 8½ x 3⅔ in
Download PDF
Booklet - simple spine 8½ x 5½ in
Download PDF
Booklet - oblong 8½ x 5½ in (spine right)
Download PDF
Booklet - wallet 7 x 4 in
Download PDF
Remit envelope #6-3/4 long flap (6.5 x 3.625 in) - outside
Download PDF
Remit envelope #6-3/4 long flap (6.5 x 3.625 in) - inside
Download PDFAlways submit designs to your USPS Business Mail Entry Unit or Mailpiece Design Analyst before production. Live DMM: DMM 201 (Physical Standards) · DMM 202 (Elements on the Face of a Mailpiece) · DMM 204 (Barcode Standards) · PostalPro