Custom Postcard Printing

Every year, billions of postcards move through the USPS system. The format works because it is cheap to print, cheap to mail, and impossible to ignore -- the recipient sees your message the moment they pull it from the mailbox. No envelope to open. No app to download.

But "custom postcard printing" covers a wide range: a 4x6 glossy promo card on 14pt stock is a different animal than a 6x11 EDDM piece on 16pt with soft-touch lamination. Size determines postage class. Paper stock determines shelf life. Coating determines whether the piece feels like a coupon or a brand statement.

This guide breaks down every decision you need to make -- size, stock, coating, printing method, finishing, and mailing -- with real pricing ranges and the USPS specs that constrain your options. If you have printed postcards before, skip to the section that matters. If this is your first run, start at the top.

What Is Custom Postcard Printing?

Custom postcard printing means you control every variable: dimensions, paper stock, coating, ink coverage, and finishing. You are not picking from a menu of three templates on a website. You are specifying a 6x9 on 14pt C2S gloss with aqueous coating on the front and a writable matte back, printed 4/4 (full color both sides), with variable data addressing and CASS-certified barcodes for presort postage.

That level of control matters because each variable affects cost, postal eligibility, and response rate:

• Size determines which USPS postage class you can use and how much real estate you have for your message
• Paper stock determines durability, perceived quality, and whether the piece survives the mail stream without bending
• Coating determines scuff resistance, color vibrancy, and whether the recipient can write on the card
• Printing method determines unit cost, color gamut, and whether you can add metallic or clear embellishments
• Finishing determines the tactile impression -- rounded corners, die-cut shapes, inline foil

The difference between a forgettable postcard and one that drives action usually comes down to getting two or three of these variables right for your specific audience and budget. A dental office mailing to 5,000 households within three miles needs different specs than a luxury real estate agent mailing 200 prospecting pieces to a curated list.

Standard Postcard Sizes and USPS Requirements

Postcard size is not just a design decision -- it is a postage decision. The USPS defines strict dimensions for each mail class, and printing a piece that is one-quarter inch too large can double your postage cost. Here are the sizes that matter:

4" x 6" -- The First-Class Standard

The most common postcard size in the industry. It qualifies for the First-Class postcard rate ($0.56 retail, as low as $0.439 presorted) as long as it stays within USPS card dimensions: minimum 3.5" x 5", maximum 4.25" x 6", thickness between 0.007" and 0.016". A standard 14pt card is approximately 0.014", so it fits comfortably. This is the go-to for appointment reminders, thank-you cards, and low-cost prospecting.

5" x 7" -- The Versatile Middle

Once you exceed 4.25" x 6", the piece no longer qualifies as a USPS "postcard" and mails at letter rates. A 5x7 mails as a First-Class letter ($0.73 retail) or Marketing Mail letter ($0.439+ presorted). The extra square footage lets you add more imagery, a coupon, or a map. Popular for event invitations, real estate just-sold cards, and retail promotions.

6" x 9" -- The Direct Mail Workhorse

The 6x9 is a flat (not a letter) under USPS rules because it exceeds 6.125" in height. It mails at flat rates via Marketing Mail -- typically $0.60-$0.80/piece depending on presort level and weight. The format gives you nearly 2.5 times the print area of a 4x6. This is the size most direct mail campaigns use when they want impact without the cost of a full 6x11.

6" x 11" -- The EDDM Minimum

Every Door Direct Mail requires a minimum piece size of 6.125" x 11.5" (or meets other USPS flat-size criteria). The 6x11 is the smallest practical EDDM postcard size that qualifies, and it is the most popular EDDM format because it minimizes paper waste while meeting the dimensional requirement. EDDM postage is $0.226/piece with no mailing list required.

Postcard Size, Postage Class, and Rate Summary

Size	USPS Class	Retail Rate	Bulk/Presort Rate	Best For
4" x 6"	First-Class Postcard	$0.56	$0.439	Reminders, thank-yous, low-cost prospecting
5" x 7"	First-Class Letter	$0.73	$0.439 (Mktg Mail)	Invitations, real estate, retail promos
6" x 9"	Marketing Mail Flat	--	$0.60-$0.80	High-impact campaigns, multi-offer layouts
6" x 11"	EDDM Retail	--	$0.226	Saturation mailing, grand openings, local service
8.5" x 11"	Marketing Mail Flat	--	$0.60-$0.80	Maximum real estate, menus, detailed offers

Critical USPS thickness rule: To mail at postcard rates, your piece must be between 0.007" and 0.016" thick. Standard 14pt cardstock is ~0.014" -- it qualifies. But if you add lamination on both sides, total thickness can push past 0.016", bumping you to letter rates. Always verify caliper with your printer before finalizing stock and coating choices.

Paper Stock Options

Paper stock is where most postcard jobs are won or lost. The stock you choose determines how the card feels in hand, how colors render, and whether the piece survives three days in a mail truck without curling or scuffing. Here are the stocks used in commercial postcard printing:

14pt C2S Gloss

The industry default. "C2S" means coated two sides -- both the front and back have a clay coating that produces a smooth surface for ink adhesion. "Gloss" means the coating has a shine. 14pt is approximately 0.014" thick and weighs about 100lb cover. Colors pop, photos look sharp, and the piece has a solid, professional feel without being heavy. This is what you get if you order postcards from most online printers without specifying otherwise.

14pt Matte

Same thickness and weight as 14pt gloss, but with a flat, non-reflective surface. Matte stock reads more upscale -- think luxury brands, financial services, law firms. Text is easier to read under overhead lighting because there is no glare. The trade-off is that colors appear slightly more muted than on gloss. Matte stock also takes pencil and pen better if the recipient needs to write on the card.

16pt C2S

Step up in thickness to approximately 0.016" -- right at the USPS postcard thickness limit. 16pt feels noticeably more rigid and premium than 14pt. It resists bending in the mail stream, which matters for larger formats like 6x9 and 6x11 that have more surface area to warp. Be aware: 16pt with lamination on both sides will exceed 0.016" and will not qualify for postcard postage rates.

100lb Uncoated

No clay coating. The paper has a natural, slightly textured feel that absorbs ink rather than sitting on the surface. Colors are more subdued, but the tactile quality signals craftsmanship. Uncoated stock is the standard for nonprofits, churches, wedding stationery, and any brand going for an organic or artisanal look. It accepts handwriting beautifully.

Coating and Lamination Options

Coating is applied after printing to protect the ink and alter the surface feel. It is not the same as the paper's built-in coating (C2S/C1S).

• Aqueous coating -- Water-based, fast-drying, applied inline on press. Provides moderate scuff protection and a slight sheen. Writable with ballpoint pen. The most common and most affordable option. Adds negligible thickness.
• UV coating -- Cured under ultraviolet light, producing a hard, high-gloss surface. Excellent scuff and moisture resistance. Not writable. Adds approximately 0.001" thickness. Best for postcards that need to survive rough handling or look glossy and premium.
• Soft-touch lamination -- A thin matte film that gives the card a velvety, almost rubbery feel. It is the most tactile finish available and significantly increases perceived value. Adds approximately 0.001-0.002" per side. Popular for luxury real estate, high-end hospitality, and brand pieces where the card itself is the statement.
• Spot UV -- UV coating applied only to specific areas (a logo, a photo, a headline) while the rest of the card remains matte. Creates a visual and tactile contrast that draws the eye. More expensive because it requires an additional press pass and a custom plate or digital mask.

When to Use Each Stock and Coating

Application	Recommended Stock	Recommended Coating
Mass EDDM campaign (restaurants, dental)	14pt C2S Gloss	Aqueous
Luxury real estate prospecting	16pt C2S or 14pt Matte	Soft-touch lamination
Nonprofit fundraising appeal	100lb Uncoated	None or light aqueous
Retail coupon / promo card	14pt C2S Gloss	UV front, aqueous back
Appointment reminder with write-in	14pt Matte	Aqueous
Premium brand statement piece	16pt C2S	Spot UV + soft-touch

How Much Does Custom Postcard Printing Cost?

Postcard pricing depends on five variables: quantity, size, paper stock, number of printed sides, and coating. Here are realistic price ranges based on current market rates for custom postcard printing -- not the loss-leader "250 free business cards" pricing that online brokers advertise, but what you actually pay for a commercial-quality job with accurate color and consistent stock.

Price Ranges by Size and Quantity

Size	Quantity	Price Range (4/4, 14pt Gloss)	Per-Piece Cost
4x6	500	$80 - $150	$0.16 - $0.30
4x6	1,000	$100 - $200	$0.10 - $0.20
4x6	5,000	$200 - $400	$0.04 - $0.08
6x9	1,000	$200 - $400	$0.20 - $0.40
6x9	5,000	$400 - $700	$0.08 - $0.14
6x11	1,000	$250 - $450	$0.25 - $0.45
6x11	5,000	$500 - $900	$0.10 - $0.18
6x11	10,000	$700 - $1,200	$0.07 - $0.12

What drives cost up:

• Heavier stock -- 16pt costs 10-20% more than 14pt due to higher paper cost and slower press speed
• Specialty coating -- Soft-touch lamination adds $0.03-$0.06/piece. Spot UV adds $0.05-$0.10/piece.
• Variable data -- Personalized names, addresses, or unique codes add $0.02-$0.05/piece for data processing and digital printing
• Odd sizes or die cuts -- Anything that is not a standard rectangle requires a custom die ($150-$300 one-time) plus slower finishing
• Rush turnaround -- Same-day or next-day service typically adds 30-50% to the base print price

What drives cost down:

• Higher quantities -- Offset printing has steep economies of scale. The difference between 1,000 and 5,000 postcards is often only 50-80% more total cost for 5x the quantity.
• Standard sizes -- 4x6, 6x9, and 6x11 run on standard cut sheets with minimal waste
• Gang-run printing -- Your job shares a press sheet with other customers. Cheaper per piece, but you give up control over exact scheduling and Pantone matching.

For a deeper breakdown of mailing costs specifically, see our guide on how much postcards cost to mail.

Printing Methods for Postcards

Two printing methods dominate commercial postcard production: digital toner and offset lithography. Each has a clear sweet spot.

Digital Printing

Digital presses print directly from a PDF file to the sheet -- no plates, no makeready, no ink-water balance to dial in. Setup cost is essentially zero, which makes digital the clear winner for short runs (under 3,000 pieces) and any job that requires variable data (unique names, addresses, barcodes, or personalized images on each piece).

MPA runs a Xerox Iridesse, which is not a standard digital press. Beyond CMYK, the Iridesse has two additional toner stations that can be loaded with metallic gold, metallic silver, clear gloss, or white toner. That means you can print a gold foil effect, a spot gloss logo, or white ink on dark stock -- all in a single pass, at digital press speed, with no plates or dies. For postcards, this is a significant differentiator: you get premium metallic and clear embellishments at the same turnaround and price point as standard digital color.

Digital postcard specs:

• Economical up to ~3,000 copies per design
• No minimum order -- print 25 or 25,000
• Variable data capable (each piece can be unique)
• Color consistency sheet-to-sheet is excellent on modern toner presses
• Metallic, clear, and white toner available (Iridesse)
• Turnaround: 1-3 business days

Offset Lithography

Offset uses etched aluminum plates, one per ink color, mounted on a press cylinder. Ink transfers from the plate to a rubber blanket to the paper (hence "offset"). The setup process -- burning plates, mounting them, running makeready sheets to dial in color -- takes time and materials. That fixed cost is spread across the entire run, so per-piece cost drops dramatically as quantity increases.

Offset postcard specs:

• Cost-effective above 3,000-5,000 copies
• Superior ink density and color gamut on coated stocks
• Pantone (PMS) spot color matching available
• Higher maximum sheet sizes for large-format postcards
• Turnaround: 5-7 business days

Digital vs. Offset Break-Even

Quantity	Better Method	Why
Under 500	Digital	No plate cost; offset makeready would exceed total print cost
500-3,000	Digital (usually)	Offset plates add $200-$400 in fixed cost that is hard to recoup at this volume
3,000-5,000	Either	Break-even zone; depends on ink coverage and stock
5,000-10,000	Offset (usually)	Per-piece cost drops below digital; color density advantage
10,000+	Offset	Significantly cheaper per piece; plates amortized across volume

One exception: if your job requires variable data (personalized postcards), digital wins at any quantity because offset cannot change the image from sheet to sheet.

Finishing and Mailing Options

Finishing is everything that happens after the sheets come off the press: cutting, coating, corner rounding, and any other physical modification to the finished card. Mailing is everything that happens after finishing: addressing, sorting, traying, and postal induction.

Finishing Options

• Standard trim -- Postcards are cut to final size on a guillotine cutter or rotary trimmer. Included in every job.
• Rounded corners -- 0.125" or 0.25" radius. Adds a softer, more modern feel. Costs $0.01-$0.02/piece on a corner-rounding machine. Popular for loyalty cards, personal brand cards, and any design going for a premium look.
• Die cutting -- Custom shapes: circles, house shapes, product silhouettes. Requires a steel rule die ($150-$300) and adds $0.03-$0.08/piece for the cutting pass. Die-cut postcards are attention-getters, but keep USPS mailability in mind -- irregularly shaped pieces may require an envelope or non-machinable surcharge.
• Scoring and folding -- A scored fold lets you create a bifold postcard (e.g., 6x11 folded to 6x5.5) with an interior panel for coupons, maps, or extended copy. The fold must be on the top or right edge for USPS mail processing.
• Perforations -- A tear-off coupon, reply card, or detachable business card built into the postcard. Common for restaurant menus, service coupons, and referral programs.

Mailing Options

If you are printing postcards to mail -- not to hand out at a trade show or leave on a counter -- the mailing method you choose has a bigger impact on total project cost than the printing itself. Here is how the options break down:

First-Class Mail: Delivered in 1-5 business days. Forwarded if the recipient has moved. Undeliverable pieces returned to sender. Best for time-sensitive communications (appointment reminders, invoices, event invitations). Presorted First-Class requires a 500-piece minimum.

USPS Marketing Mail (formerly Standard Mail): Delivered in 3-10 business days. Not forwarded or returned by default (you can pay for these services). Requires a 200-piece minimum. This is what most direct mail campaigns use because the postage savings over First-Class are significant -- especially at higher presort levels.

EDDM (Every Door Direct Mail): The lowest postage rate at $0.226/piece. No mailing list required -- you select postal routes on the USPS EDDM tool and your piece goes to every residential or business address on those routes. Minimum 200 pieces per carrier route, maximum 5,000 per day per ZIP code. Your postcard must meet flat-size minimums (6.125" x 11" or equivalent). Perfect for local businesses: restaurants, dental offices, HVAC, roofing, political campaigns.

For more on EDDM strategy and design, see our guides on EDDM postcard sizes and EDDM postcard design tips.

Nonprofit Mail: Qualifying 501(c)(3) organizations get the lowest presort rates. Nonprofit Marketing Mail runs approximately $0.148/piece at automation rates. If your organization qualifies, the postage savings on a 10,000-piece campaign can exceed $2,000 versus standard Marketing Mail.

Print-and-Mail Under One Roof

Most postcard jobs involve two vendors: a printer and a mail house. The printer produces the cards, boxes them, and ships them to the mail house. The mail house receives the shipment, verifies the count, runs the addressing, sorts to USPS requirements, and trucks the trays to the post office. That handoff adds 3-5 business days and creates risk -- damaged cards in transit, miscounts, lost shipments.

MPA eliminates that handoff. We print, address, sort, and induct your postcards from a single facility in Lakeland, FL. Same building. Same team. The cards go from press to mail stream without ever leaving our dock. That saves time, reduces errors, and gives you a single point of accountability if anything goes wrong.

How to Design an Effective Postcard

Design is where most postcard campaigns fail -- not because the printing was bad, but because the layout ignored print production realities and direct mail best practices. Here is what to get right:

File Setup for Print

• Bleed: Add 0.125" (1/8 inch) of bleed on all four sides. Bleed is the area beyond the trim edge where your background color or image extends. Without bleed, you risk a thin white line along the edge after trimming. If your finished postcard is 4" x 6", your file should be 4.25" x 6.25".
• Safe zone: Keep all critical content -- text, logos, phone numbers -- at least 0.25" (1/4 inch) inside the trim edge. Content closer to the edge risks being cut off due to normal trim variation (typically +/- 1/16").
• Resolution: 300 DPI minimum for all images. 150 DPI looks fine on screen but prints soft and muddy. Vector graphics (logos, icons, text) should remain as vectors, not rasterized.
• Color mode: CMYK for offset printing. Digital presses accept RGB but convert to CMYK internally -- submitting CMYK gives you more predictable color. If you have Pantone brand colors, note the PMS numbers on your order.
• File format: Press-ready PDF with fonts embedded or converted to outlines. No spot colors unless you are paying for PMS ink. No transparency left unflattened.

Design for Response

The goal of a direct mail postcard is not to be beautiful. It is to produce a response: a phone call, a website visit, a QR code scan, a store visit. Every design element should serve that goal.

• One clear CTA: "Call 555-1234 for a free estimate." "Scan to book your appointment." "Bring this card in for 20% off." One action, stated clearly, with a visual hierarchy that makes it the most prominent element on the address side. Multiple CTAs dilute response rates.
• Headline on the non-address side: The front of the postcard (the side without the address) is your billboard. Lead with the benefit, not your company name. "Your Roof Is 15 Years Old" works harder than "ABC Roofing Company."
• QR code: Place it on the address side, bottom-left quadrant, at least 0.75" x 0.75" for reliable scanning. Link it to a dedicated landing page -- not your homepage -- with tracking parameters so you can measure response.
• Tracking URL: Even if you include a QR code, add a short vanity URL (e.g., yoursite.com/spring24) for recipients who prefer to type. Use UTM parameters for analytics.
• White space: Crowded postcards get thrown away. Give your headline and CTA room to breathe. If you cannot fit your message comfortably, you need a larger postcard, not smaller type.

Common Design Mistakes

• No bleed: You get a white border on one or more edges. It looks amateur.
• Text too close to the edge: The trimmer cuts off the last digit of your phone number. Your CTA is gone.
• Low-resolution images: Photos pulled from a website at 72 DPI print at roughly 1/4 their screen size at 300 DPI. They look pixelated and blurry.
• Ignoring the postal indicia area: The USPS requires specific clear zones for barcodes, return address, and postage on the address side. Design around these areas, not over them.
• Dark background on the address side: Inkjet addressing prints white or clear -- it will not show on a dark background. If your address side has a dark design, leave a white or light-colored address block.

Frequently Asked Questions

What is the minimum order for custom postcard printing?

At MPA, there is no minimum order on digital postcard printing. You can order as few as 25 postcards on our Xerox Iridesse press. Offset printing typically requires 3,000+ copies to be cost-effective, but digital has no practical floor. Most customers ordering under 500 pieces choose digital.

What size postcard qualifies for USPS First-Class postcard rates?

To qualify for the $0.56 First-Class postcard rate, your piece must be between 3.5" x 5" and 4.25" x 6" and no thicker than 0.016". The standard 4x6 is the most popular qualifying size. Anything larger mails at letter or flat rates, which cost more per piece. See the size and postage table above for a full comparison.

How long does custom postcard printing take?

Digital postcard printing typically ships in 2-3 business days from proof approval. Offset runs of 5,000+ pieces take 5-7 business days. If you need print-and-mail service, add 1-2 days for addressing, sorting, and postal induction. Rush turnaround is available for digital jobs -- ask when you request your quote.

What file format should I use for postcard printing?

Submit a press-ready PDF at 300 DPI with 0.125" bleed on all sides and fonts converted to outlines. CMYK color mode is required for offset; digital presses accept both CMYK and RGB but CMYK gives more predictable color. Avoid placing critical text or logos within 0.25" of any trim edge.

Can I print and mail postcards from the same facility?

Yes. MPA prints, addresses, sorts, and inducts postcards under one roof in Lakeland, FL. This eliminates shipping between a printer and a mail house, saving 3-5 days and reducing damage risk. We handle First-Class, Marketing Mail, EDDM, and nonprofit postage classes.

What is the difference between UV coating and aqueous coating?

UV coating is a glossy, hard-cured finish applied by passing the sheet under ultraviolet light. It is the most durable option and resists scuffing, but cannot be written on with pen. Aqueous coating is water-based, dries quickly, and is writable -- making it better for postcards with a reply area or fill-in fields. Both protect ink from smearing during mail processing.

Do I get a proof before my postcards are printed?

Yes. MPA provides a free digital PDF proof on every job. You review layout, spelling, and color before we go to press. For jobs where color accuracy is critical -- brand Pantone matching, photography reproduction -- we offer a hard-copy press proof for an additional fee.

What is EDDM and can I use it with custom postcards?

EDDM (Every Door Direct Mail) delivers your postcard to every address on selected postal routes without needing a mailing list. Postage is $0.226/piece. Your postcard must be at least 6.125" x 11" and cannot exceed 12" x 15". The 6x11 and 6.5x9 are the most popular EDDM postcard sizes. It is the most cost-effective way to reach every household in a geographic area.

Why MPA for Custom Postcard Printing

Mail Processing Associates has been printing and mailing from Lakeland, FL since 1989. We are veteran-owned, SOC 2 Type 2 certified, and HIPAA compliant -- which matters if you are mailing for healthcare, financial services, or any industry that handles protected information.

Here is what sets us apart for postcard work specifically:

• Xerox Iridesse press: Metallic gold, metallic silver, clear gloss, and white toner in a single pass. Premium postcard effects at digital speed, with no plates or dies.
• Print and mail under one roof: No shipping your cards to a separate mail house. We print, address, sort, and induct from the same facility.
• No minimums on digital: Order 50 postcards or 50,000. Same quality, same turnaround commitment.
• EDDM expertise: We handle EDDM campaigns from route selection through postal induction at $0.226/piece.
• SOC 2 + HIPAA compliance: Secure handling for sensitive mailings -- patient reminders, financial disclosures, insurance communications.
• Free proofs on every job: You approve before we print. No surprises.

Whether you need 200 postcards for a real estate farming campaign or 50,000 for a regional EDDM blitz, we have the equipment, the postal expertise, and the compliance certifications to handle it.