Question
How does paper weight affect flyer mailing costs?
Answer
Paper weight feeds directly into mailing cost, because postage is priced by weight brackets. A heavier stock can tip an otherwise cheap mailer into a higher postage tier, and across thousands of pieces that difference adds up fast. For large direct mail campaigns, staying with a lighter text weight keeps each piece under common thresholds.
- Postage is bracketed by weight, so a small increase per piece can cross a pricing line.
- 80 lb text is a common choice for big mailings because it keeps pieces light.
- At scale, shaving weight on each flyer multiplies into meaningful postage savings.
- Balance the feel you want against the postage tier your weight lands in before finalizing.
| Goal | Weight strategy |
|---|---|
| Lowest postage | Lighter text stock (80 lb) |
| Premium feel | Heavier stock, higher postage |
| High-volume campaign | Stay under weight thresholds |
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