Rigid Envelopes: What Qualifies As Rigid For Mailing?

what constitutes rigid when mailing letter size envelopes

The definition of rigid is found in the USPS Domestic Mail Manual, which states that a letter-size piece is non-machinable if it is too rigid and does not bend easily. The USPS defines rigid envelopes as those that are not flexible and flat, and those that cannot fit through USPS mail processing machines. The cost of sending rigid envelopes is higher than that of sending machinable envelopes.

Characteristics Values
Minimum dimensions 3-1/2 inches high x 5 inches long x 0.007 inch thick
Maximum dimensions 6-1/8 inches high x 11-1/2 inches long x 1/4 inch thick
Weight Up to 3.5 oz for First-Class Mail
Shape Rectangular
Contents Flat, flexible items like letters, cards, checks, forms, paper goods, stickers, photos, trading cards
Rigidity Bends easily, passes through USPS mail processing machines

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Definition of rigid

The definition of "rigid" is important when mailing letter-size envelopes because it determines whether the mailpiece is considered "nonmachinable" and therefore subject to a higher postage rate. According to the USPS Domestic Mail Manual, a letter-size piece is nonmachinable if it is "too rigid (does not bend easily when subjected to a transport belt tension)".

In simple terms, rigid mailpieces are those that do not bend easily and are therefore difficult to process through postal machines. This includes items such as flash drives, coins, keys, and hard plastic card cases. If such items are sent loose in unpadded paper envelopes, they could tear out of the envelope, jam sorting machines, cause delays, or get lost.

To avoid these issues, the USPS recommends sending rigid objects in padded envelopes or small boxes and mailing them as packages. This ensures that the items are adequately protected and can be safely processed through the postal system.

It is worth noting that the definition of "rigid" can be somewhat subjective, and different postal clerks may have varying opinions on whether a particular mailpiece is considered rigid. However, as a general rule of thumb, if a mailpiece can be easily bent with your fingertips, it is likely not considered rigid.

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Cost of mailing rigid envelopes

The cost of mailing rigid envelopes depends on several factors, including the size, weight, and shape of the envelope, as well as the mailing service used. In the United States, the USPS (United States Postal Service) defines a "letter-size piece" as non-machinable if it is "too rigid and does not bend easily when subjected to a transport belt tension". This means that rigid envelopes cannot be processed using the standard machines and require manual sorting, which incurs additional labour expenses.

USPS offers First-Class Mail as a low-cost option for sending envelopes. The cost of mailing a standard-sized, rectangular envelope starts at $0.73 for First-Class Mail Forever stamps, which will never expire even if the postage rate increases. However, non-machinable envelopes with rigid characteristics may be subject to a non-machinable surcharge, resulting in higher costs. Square, oversized, or unusually shaped envelopes also start at a higher price point of $1.19.

The weight of the envelope is another factor that affects the cost. First-Class Mail letters have a maximum weight limit of 3.5 ounces, and the price increases with weight. For large First-Class Mail envelopes, the maximum weight allowed is 13 ounces. Additionally, all envelopes must be rectangular; otherwise, there may be an additional charge for irregular shapes.

The size of the envelope is crucial, with specific dimensions required for letters and large envelopes (flats). Letters should be at least 3.5 inches high, 5 inches long, and 0.007 inches thick, while the maximum dimensions are 6-1/8 inches high, 11.5 inches long, and 1/4 inch thick. Large envelopes or flats start at a higher price point of $1.50 and have different size requirements.

To optimize costs, businesses can take advantage of bulk discounts offered by USPS for First-Class Mail commercial pricing. This applies to presorted letters and flats with a minimum quantity of 500 mailpieces, providing a cost-effective solution for promotional messages.

Overall, the cost of mailing rigid envelopes can vary depending on their classification as letters, flats, or packages, with surcharges for non-machinable and irregularly shaped items. USPS offers affordable options like First-Class Mail, and businesses can further reduce expenses by utilizing bulk discounts and designing mailers that meet size and weight requirements.

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Size requirements for letter-sized envelopes

The USPS definition of "rigid" is found in §101.1.2(e) of the USPS Domestic Mail Manual. According to the manual, a letter-size piece is non-machinable if it is too rigid and does not bend easily when subjected to transport belt tension. This means that if an envelope is rigid, it cannot be processed by the USPS's high-speed sorting machines and will require a trained clerk to hand-sort it by address.

When mailing letter-sized envelopes, it is important to ensure that they meet the size requirements to avoid additional charges. Here are the size requirements for letter-sized envelopes:

  • Minimum dimensions: 3.5 inches high x 5 inches long x 0.007 inch thick.
  • Maximum dimensions: 6-1/8 inches high x 11-1/2 inches long x 1/4 inch thick.

It is important to note that envelopes must be rectangular and made of paper to qualify for letter prices. If your envelope exceeds the maximum dimensions, it may be considered a large envelope or "flat", which has different postage rates. Additionally, if your envelope is non-rectangular, rigid, lumpy, or has clasps, string, or buttons, it will be considered nonmachinable and may incur a surcharge.

To avoid paying extra postage, it is recommended to use wafer seals or tabs to close the open sides of folded mailpieces. You can also contact a Mailpiece Design Analyst (MDA) to precisely measure the thickness of your envelope and ensure it meets the requirements.

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Examples of rigid objects

In the context of mailing letter-size envelopes, the USPS defines "rigid" in §101.1.2(e) of the USPS Domestic Mail Manual as "a letter-size piece [that]... [i]s too rigid (does not bend easily when subjected to a transport belt tension". This definition is quite subjective, and there is a lot of confusion around it, with different postmasters and clerks having different opinions. However, if a letter-size piece exceeds the dimensions of 6+1/8” in height, 11-1/2” in length, and 1/4" in thickness, it is considered a large envelope or parcel and will be subject to a non-machinable surcharge. This is because mailpieces that are rigid, square, or unusually shaped often jam postal equipment and are difficult to process.

Now, let's look at some examples of rigid objects in general:

  • A ball bearing made of hardened steel is considered a rigid body. When bouncing or tapping, it loses almost no mechanical energy and retains its shape.
  • A bridge that consistently supports tons of weight can be considered a rigid body. While it may undergo slight deformation, the motion experienced is negligible compared to its structure.
  • The wing of an aeroplane can be considered a rigid body during flight, as the motion it experiences is minimal.
  • In everyday life, solid bodies like tables and mobile phones can be considered rigid.

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Mailing rigid objects

When mailing rigid objects, it is important to be mindful of the potential for additional charges. Items that are rigid, square, or unusually shaped often jam postal equipment and are therefore subject to a non-machinable surcharge. This includes envelopes that are lumpy, have clasps, string, or buttons. To avoid these extra costs, it is recommended to use a padded envelope or small box and send the item as a package.

The size of the envelope also plays a crucial role in determining the cost of mailing rigid objects. First-Class Mail letters have specific size requirements, including minimum and maximum dimensions. Letters must be at least 3-1/2 inches high, 5 inches long, and 0.007 inches thick. The maximum dimensions are 6-1/8 inches high, 11-1/2 inches long, and 1/4 inch thick. If your rigid object exceeds these dimensions, you may need to pay the package price, which is typically higher.

To ensure your rigid item can be processed by the postal service without issues, it is important to package it securely. Envelopes must be rectangular and made of paper to qualify for letter prices. If your envelope is non-rectangular, rigid, or lumpy, it will likely be classified as a package. Additionally, avoid sending rigid objects in paper envelopes as they can tear, jam sorting machines, or get lost. Opt for padded envelopes or small boxes to protect your item and ensure safe delivery.

Frequently asked questions

According to the USPS Domestic Mail Manual, a letter-size piece is non-machinable if it is too rigid and does not bend easily when subjected to transport belt tension.

Items such as flash drives, coins, keys, and hard plastic card cases are considered rigid by USPS. These items should not be sent in unpadded paper envelopes as they could tear out of the envelope, jam sorting machines, cause delays, or get lost.

Sending rigid items in letter-size envelopes may incur a non-machinable surcharge. For example, First-Class Mail letters with one or more non-machinable characteristics, such as rigidity, will be subject to an additional charge.

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