How Postcard Size Affects Printing & Mailing Costs
Why Postcard Size Is Your First Pricing Decision
Choosing the right postcard size isn't just about design — it directly impacts three major cost factors:
• Material usage (how much paper you're buying)
• Press efficiency (how many cards fit on a press sheet)
• USPS postage rates (size thresholds trigger different pricing tiers)
USPS Postcard Size Requirements
Before diving into pricing, understand USPS size rules. Postcards must meet specific dimensions to qualify for postcard postage rates.
USPS Postcard Minimum
• At least 3.5" x 5"
• At least 0.007" thick (roughly 12pt cardstock
USPS Postcard Maximum (Standard Rate)
• No larger than 6" x 9"
• No thicker than 0.016" (roughly 18pt cardstock)
Important: Anything larger than 6" x 9" is classified as a "letter" or "flat" and incurs higher postage surcharges — typically $0.15–$0.25 more per piece.
Standard Postcard Sizes & Cost Comparison
4" x 6" Postcards
Material Cost: LOWEST
A 4x6 postcard uses the least amount of paper stock. On a standard 25" x 38" press sheet, you can fit 36–40 cards. That's maximum efficiency.
Press Efficiency: HIGHEST
More cards per sheet = lower setup cost per piece.
USPS Postage: LOWEST
• First Class: ~$0.55 per piece
• Marketing Mail: ~$0.19–$0.24 per piece
• EDDM: ~$0.21 per piece
Best For:
• High-volume mailings
• Budget-conscious campaigns
• Event reminders, appointment cards, thank-you notes
Cost Per Piece Estimate (4x6, 14pt, 4-color, UV coating):
• 500 pieces: $1.50–$1.80 each
• 2,500 pieces: $0.60–$0.75 each
• 10,000 pieces: $0.35–$0.45 each
5.5" x 8.5" Postcards
Material Cost: MODERATE
Uses about 90% more material than a 4x6, but still fits efficiently on standard press sheets.
USPS Postage: STANDARD
• First Class: ~$0.55 per piece
• Marketing Mail: ~$0.22–$0.28 per piece
Best For:
• Real estate postcards, retail promotions with coupons
• Multi-offer layouts
Cost Per Piece Estimate:
• 500 pieces: $1.75–$2.10 each
• 2,500 pieces: $0.70–$0.85 each
• 10,000 pieces: $0.40–$0.52 each
6" x 9" Postcards
Material Cost: HIGH
Uses 125% more material than a 4x6. It's the largest size that still qualifies for standard USPS postcard postage.
Best For:
• Premium campaigns where impact matters
• Full-color photography or complex designs
• High-margin offers (real estate, luxury services, B2B)
Cost Per Piece Estimate:
• 500 pieces: $2.10–$2.50 each
• 2,500 pieces: $0.85–$1.05 each
• 10,000 pieces: $0.50–$0.65 each
Frequently Asked Questions
What's the most popular postcard size?
The 5.5" x 8.5" postcard is the most common size for direct mail campaigns. It balances design space, cost, and standard USPS postage rates.
Does a bigger postcard get better response rates?
Sometimes. Larger postcards stand out in the mailbox and allow for more compelling visuals. However, response rates depend more on targeting, offer, and design quality than size alone.
What size should I use for EDDM?
EDDM works with any size up to 6" x 9". The 6" x 9" format is popular for EDDM because it maximizes visibility while keeping postage costs low ($0.21–$0.24 per piece).
Get a Custom Quote for Your Postcard Size
Send us your specs, and we'll provide a detailed cost breakdown within 24 hours.
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