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hyasnthgrl · ‎01-14-2023

If you are using a poly mailer to ship an item First Class, can you ship a 6" x 9" item (sewing pattern) in a 9 1/2" x 11 1/2" poly mailer? Just wondering if there can be extra room or does it need to fit exactly? Seems like a silly question, but at one time the P.O. told me the 6" by 9" pattern could not have excess inches. Can't remember if it was being mailed international. I want to take advantage of my shipping supply coupon, but the 6 1/4" by 8 1/2" envelope is too small, especially if I include more than one pattern in the envelope. Do you have to tape the excess inches to fit the pattern exactly?

wastingtime101 · ‎01-14-2023

Sure, there's no problem with using an envelope larger than the item. But I'd put the item inside a plastic bag and sandwich it between cardboard with corrugation facing opposite directions so the item isn't bent, crushed, torn, etc.

You don't have to tape the excess down.

Walk without rhythm, it won't attract the worm.

nobody*s_perfect · ‎01-14-2023

The maximum dimensions for a First Class letter are "Not more than 11-1/2 inches long, or more than 6-1/8 inches high, or more than 1/4-inch thick." So if you're starting with an envelope with a dimension over 11.5 or 6.125, you have to make it smaller, such as by folding under, while also not making the thickness more than .25 inch. Probably it's not possible to get the width of the envelope containing a 6-inch pattern to be under that 6 and 1/8 inch limit.

For a flat (AKA Large envelope) the limit is "Not more than 15 inches long, or more than 12 inches high, or more than 3/4 inch thick." So your proposed envelope that's 11.5 by 9.5 would be OK, with no modifications needed. However, as you probably already know, flats must be flexible, and an envelope with two patterns would probably not meet the USPS criteria for flexibility.