Are you thinking about using a CD or DVD for your next direct mailing campaign? Mailing a disc certainly has different rules from a postcard or catalog. Here’s a few important pointers you should consider to lower your costs significantly:

1. Having a ‘machinable’ mail piece will lower mailing cost significantly, this means it is compatible with postal service sorting machinery therefore can be handling automatically.
Dimension and weight standard for machinable mail pieces:
a. Height, not more than 6 inches or less than 5.5 inches high.
b. Length, not more than 9.75 inches or less than 7.25 inches long.
c. Thickness, not more than 0.25 inch or less than 0.009 inch thick.
d. Weight, not more than 3 ounces.
e. Within an aspect ratio (length divided by height) of 1.3 to 2.5, therefore square mailers do not qualify as machinable.

2. Most commonly used direct mailing piece for CDs and DVDs include plain vanilla envelopes and self mailing cardboard mailers. Do not use padded envelopes because it is non-machinable.

3. When mailing in a plain envelope it’s a good idea to place the disc in a protective sleeve first. Cardboard mailers should be made with industry standard 75lbs or greater.

4. Jewel cases, amaray cases and other plastic cases are not suitable for mailing because of their thickness and tendency to crack.

For more detailed guidelines on direct mailing check USPS Direct Mail Manual.