Booklets

How to design letter sized booklets

Booklets must have a bound edge. Sheets that are fastened with at least two staples (one staple starting Jan 5, 2013) in the manufacturing fold (saddle stitched), perfect bound, pressed-glued, or joined together by another binding method that produces an end at which pages are attached together are considered booklets. Booklets are open on three sides before sealing, similar in design to a book. In general, booklets must be uniformly thick. Large bound booklets that are folded for mailing qualify for automation and non-machinable prices if the final mail piece remains nearly uniform in thickness. Three 1.5 inch-wide tabs (wafer seals) are required; see chart below.

Booklets go at the “letter” postage rate. Bound pieces that are larger than “booklet size” are mailed at the more expensive “flats” rates and do not have to be tabbed. The maximum size for booklets is 6 x 10.5 inches (see chart).

Physical standards for booklets
Height: 3.5 to 6 inches
Length: 5 to 10.5 inches (see chart for exceptions)
Thickness: 0.009 to 0.25 inches
Weight: not more then 3 ounces
Aspect Ratio: within 1.3 to 2.5
Cover Stock Requirements: See Chart

Click on chart to enlarge.


Paper basis weight conversion table

Paper basis weight is based on the weight of 500 sheets of:

  • 25 x 38 inch sheets of book-grade paper
  • 17 x 22 inch bond-grade paper
  • 20 x 26 inch sheets of cover-grade paper
  • 24 x 36 inch sheets of newsprint

For example, if 500 sheets of book-grade paper weigh 39 pounds, the paper is considered 39-pound book paper.

Book Weight Bond Weight Cover Weight Newsprint Weight
39 15 21 35
40 16 22 36
50 20 27 45
55 22 30 50
60 24 33 55
70 28 40 64
75 30 41 68
80 31 44 73
90 36 50 82
100 40 56 91
110 44 60 100
128 50 70 116

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