technically I believe it's supposed to be 3" x 1" but no one is going to give you a problem about it. You can even just write "local postal customer" somewhere on the piece and as long as it's contained in some kind of box it will be totally fine.

EDDM is processed at the retail counter where all they really care about is whether the postage is paid or not.

Thanks for the info.

The Post Offices around here may be a little more strict than your's. The first time I did an EDDM campaign I made up post cards at the smallest size allowed. When I got to the counter the woman told me that the post card was too small so they wouldn't send them out. I stood there with 4,000 printed cards ready to "go postal". After arguing with her, she finally took out the tape measure and measured the card, then took her time to lookup what the size requirement was.

So now I am a little worried about getting things correct.

If you want to be 100% compliant, make the indicia (the square box) 1"x1" and the address box 3"x1", as long as you have the wording in there they have to take it.

You'll also need to make sure they're not crossing the center of the piece, but anywhere else is OK. Just make sure your piece is the right size too but it seems like you've got that down.

No problem at all, I hope you have some success with your mailing. You can go a little smaller but it's not a typical size you'll find printers doing ... you can go down to 6.5x7. Technically you could go 6.25x6.5 if you wanted and that would qualify but 6.5x9 is the closest standard size.

How many are you printing? They can get really heavy, expect each box to be 30-50 pounds, containing 500-700 cards each.

You can bundle very quickly if you just count out 100 and then just eyeball other stacks to the same height, you'll be pretty much dead on each time if you just use one as a reference. Kudos to Doran Peck on here for teaching me that.

The last time I did 4,000. This time I am going to do about 5,000.

That's a good idea about counting out the cards by using a stack. That's the same way that dealers count chips in Las Vegas so it's good enough for me

I'm doing 5,000 EDDM larger postcards fairly soon. I am using a printing service, they don't charge much extra to print/sort/deliver etc... Yep the post office said standard postcard size isn't allowed. USPS has an informative site on EDDM as well as a map/list of routes for you to choose.