Folded mailers
A self-mailer that opens the way you designed it to open, because the score was cut for the stock.
- Bi
- Tri
- Gate
Sizes
Build to the bleed dimension; keep live copy inside the safe area.
| Size | Trim | With bleed | Safe area | Minimum stock |
|---|---|---|---|---|
| 6" × 9" | 6" × 9" | 6.25" × 9.25" | 5.75" × 8.75" | 14pt cover |
| 5.5" × 8.5" | 5.5" × 8.5" | 5.75" × 8.75" | 5.25" × 8.25" | 100lb text |
| 8.5" × 11" | 8.5" × 11" | 8.75" × 11.25" | 8.25" × 10.75" | 100lb text |
How to set the file up
- Supply a flat file with fold marks on a separate layer.
- Allow for panel creep on tri-folds — inner panels are trimmed narrower.
- Keep heavy ink coverage off the score line.
- Self-mailers need a tab or seal; confirm the mailing class before final artwork.
Folded mailers — questions we get
- Will a heavy stock crack when it folds?
- Not if it is scored first. We score on press to the caliper of the sheet, which crushes the fibre in a controlled line rather than letting the fold tear it. Uncoated cover always gets this treatment.
- What is panel creep and do I need to care?
- On a tri-fold, the innermost panel has to be a few millimetres narrower or it hits the fold and buckles. We adjust it at imposition — you only need to care if you are supplying a pre-imposed file.
- Can a folded mailer go through the post without an envelope?
- Yes, with a tab or seal and the right dimensions for the class you are mailing. Confirm the class before final artwork, because it decides both size and thickness.
- Can the fold run through a foiled area?
- It can, but foil is a film sitting on the surface and a hard fold through it will eventually show a hairline. We either keep the foil off the score or use a softer stock that folds without the sharp break.
- Which fold should I use?
- Bi-fold for one big reveal, tri-fold for a sequence, gate for a piece where both halves open onto a single image. The fold is a sequencing decision before it is a production one.