How USPS Format and Logistics Changes Will Impact Direct Mail Campaigns in 2026

For marketers who rely on direct mail, postage costs and logistics can make or break a campaign’s ROI. While 2026 brings some good news — stable postage rates early in the year — there are also important operational changes coming that will affect how mail is priced, entered, and designed.

From the elimination of Network Distribution Center (NDC) discounts to upcoming zone-based pricing and tighter format compliance enforcement, these shifts will influence both mailing costs and production strategy.

Here’s what marketers and agencies need to know to stay ahead.

The End of NDC Entry Discounts

One of the biggest changes underway is the elimination of discounts for Network Distribution Center (NDC) entry.

For years, mailers could save by entering bulk mail directly at NDCs — regional USPS hubs that helped consolidate mail closer to its delivery destination. These entry discounts offered meaningful savings for large-scale campaigns.

Starting in 2025 and rolling into 2026, USPS is phasing out those discounts, which means the cost advantage for NDC entry will disappear.

What this means for marketing teams:

• Mailing costs may rise slightly for pieces previously dropped at NDCs.

• Production schedules may need adjusting as mailers shift to the Sectional Center Facility (SCF) or destination entry strategies.

• Partnerships with experienced print-mail providers become more valuable, since optimizing entry methods and logistics will be key to controlling costs.

If you’ve relied on NDC entry pricing in past campaigns, now is the time to review your logistics plan and mailing footprint.

Zone-Based Pricing on the Horizon

USPS has also announced plans to move toward zone-based pricing for Marketing Mail and other services as early as January 2026.

Currently, most direct mail pricing doesn’t depend on distance — you pay the same rate whether your mail travels 50 miles or 1,500 miles. Zone-based pricing would change that by linking postage costs to delivery distance, similar to how parcel shipping works.

The impact for marketers:

• Mail traveling farther from the point of entry may become more expensive.

• Localized campaigns could see cost savings if entered near their destination.

• Regional printing and distributed mail entry may become cost-efficient alternatives for national mailers.

This shift rewards efficiency — both in targeting and in production strategy. Working with a partner who can manage multi-site print and mail entry will help marketers minimize costs under the new system.

Tighter Mail Piece Format Compliance

USPS is also stepping up format enforcement for all types of mail. This means stricter adherence to size, aspect ratio, thickness, and tabbing requirements.

Mail pieces that don’t meet automation standards risk being reclassified to a higher rate or rejected altogether.

Key areas of focus:

• Self-mailers: Must meet new tabbing and folding standards.

• Thickness and rigidity: Pieces that fall outside limits may lose automation eligibility.

• Address placement and barcode location: Errors can slow processing or trigger surcharges.

Why it matters:

These rules aren’t just technical details — they directly affect your postage rate and delivery time. Non-compliant pieces can cost 10–30% more per piece due to reclassification.

Design and print alignment are more critical than ever. Working with a digital printing partner who understands USPS specifications ensures every piece meets the latest standards and moves through the system efficiently.

What Marketers Should Do Now

1. Review your entry strategy. If your campaigns rely on NDC entry, discuss SCF or commingling alternatives with your print partner.

2. Prepare for zone pricing. Start mapping where your customers are and how far your mail travels — location data will soon influence postage costs.

3. Audit your mail formats. Make sure your creative team understands new automation specs before finalizing designs.

4. Leverage expert support. Choose a print and mail partner who can handle logistics, data, and compliance seamlessly.

These updates may feel technical, but for marketers, they translate directly into budget, delivery speed, and campaign performance.

The Bottom Line

The USPS changes in format, entry, and logistics aren’t just operational updates — they’re strategic opportunities.

Brands that adapt early will gain an edge in efficiency, compliance, and cost control. By partnering with a knowledgeable digital print provider, you can ensure your mail reaches the right audience, at the right cost, every time.