Full Color Return Envelopes

Yes. A USPS barcode can be included in your custom envelope design to help with automated mail processing. If you need to generate a barcode, USPS provides an online Encoder/Decoder tool.

A USPS Intelligent Mail® barcode can help USPS process and route eligible mail more efficiently. Many business envelopes can accommodate a barcode, but the correct barcode and placement depend on the envelope size, mailing type, address layout, and USPS mailing requirements.

For qualifying letter-size mail, an Intelligent Mail barcode may generally be placed:

• In the address block, or
• In the USPS barcode area near the lower-right portion of the mailpiece.

The exact location, clear space, dimensions, and print quality must meet USPS requirements. USPS defines the barcode clear zone for letter-size pieces as the lower-right area extending 4¾ inches from the right edge and ⅝ inch from the bottom edge.

For flat-size mail, different barcode placement requirements apply.

Barcodes may be used with qualifying window envelopes. However, the address and barcode must remain properly positioned and visible through the window even when the insert moves inside the envelope. USPS requires adequate clear space around the address and barcode.

The type of barcode you need depends on your mailing. For commercial or automation mailings, you may need an Intelligent Mail barcode containing specific routing and mailing information.

Because barcode requirements can vary by mailing program, we recommend confirming your barcode with USPS or your mailing provider before submitting your envelope artwork for printing.

If you order custom envelopes, you can include a properly prepared USPS barcode in your design. Make sure the barcode meets current USPS specifications and is positioned correctly before submitting your order.

If you're unsure whether your envelope size or design can accommodate your barcode, contact us before ordering and we'll help determine whether it can be incorporated into the printed design.

Yes. You can include a properly prepared USPS barcode in your custom envelope order:

• Adding it yourself: You can provide print-ready artwork with your USPS barcode already included and positioned to current USPS guidelines for all custom envelope orders.
• Having us add it: If you provide your required barcode details, our graphics team can add the USPS barcode to your custom envelope order for an additional graphic design fee.

Note: Before submitting your order, we recommend verifying that your barcode layout and envelope size meet current USPS placement requirements, or contacting us ahead of time for guidance.

When a barcode is requested on a return envelope, the U.S. Postal Service (USPS) will generate one and may provide a PDF preview of the envelope layout.

Our system generates a new barcode for security purposes based on your address, extended ZIP code, and the type of envelope ordered. Because of this, our printed envelope may not look identical to the PDF provided by USPS. However, we guarantee that our system-generated barcodes work and are fully compatible with USPS standards.

USPS requires businesses to obtain a Mailer ID (MID) to include an Intelligent Mail® Barcode on return envelopes. The Intelligent Mail® Barcode system is the standard format used by USPS to sort and track letters and flat mail efficiently.

1. Obtain a permit: Fill out USPS Form PS3615 to apply for a permit with your local post office. (Note: One-time application fees and/or annual permit fees apply in addition to standard postage costs).

2. Submit permit: Drop off the completed permit form at the local post office where you plan to mail your envelopes.

3. Register online: Create and manage your business account at usps.com.

4. Request a Mailer ID: Apply for a Mailer ID through the USPS online business portal. (If you encounter an exception regarding your required Mailer ID type or quantity, refer to the USPS Mailer ID Application Guide).

5. Place your order: Submit your envelope order with your Mailer ID and extended ZIP code included.

A Mailer ID is a 6-digit or 9-digit identification code assigned by USPS based on your annual mail volume:

• 9-digit Mailer IDs: Typically assigned to businesses without specific minimum volume requirements.
• 6-digit Mailer IDs: Assigned to higher-volume mailers.

An Intelligent Mail® Barcode is a sorting and tracking barcode format used by USPS for letters and flats. It replaces older formats (such as POSTNET™ and Planet Code®) by using four distinct vertical bar types. This design encodes significantly more tracking and routing data while taking up less physical space on your printed envelopes.