The Ultimate Wedding Invitation Mailing Guide: Postage Costs, Hand-Canceling & USPS Tips

EducationPlanning & Design
Written By Luke Gasbarro

Most people haven’t tackled a mass mailing until their wedding. And trust us, sending out 100+ invitations is a whole different beast than dropping holiday cards once a year.

Wedding invites are heavier, layered, and often include all kinds of beautiful extras. Now mix in the recent USPS price hikes this year, extra fees for square envelopes, and that dreaded “non‑machinable” surcharge. Things just got complicated real fast.

It’s a lot. This guide cuts through the confusion, showing what really costs more, what keeps your invites safe, and what you should know to mail them with zero surprises. Plus, there’s a downloadable Lucasano Mailing Guide at the bottom for you to reference later.

Contents

Mailing wedding invites is not as easy as slapping on a Forever Stamp. That might be true for your Save-The-Date, but for most wedding invitations, that stamp is probably not going to cut it. Here’s what bumps up the cost:

Extra Ounces = Extra Money

A Forever Stamp covers up to one ounce. But wedding invites usually include more than just a card—it may include a RSVP card, details and/or map cards, ribbon, or wax seal. All those beautiful extras add weight.

Each additional ounce = 29¢

For example, a standard wedding suite with an invitation, outer envelope, RSVP card, and response envelope typically weighs a little over an ounce. That means you’ll need:

78¢ Forever Stamp + 29¢ for the extra ounce = $1.07

Using thicker cardstock or including embellishments? That will bump the weight even more, or make the envelope stiff enough to trigger another USPS surcharge—non-machinable.

USPS rates went up again on July 13, 2025

USPS uses machines to process most mail. It’s fast, efficient, and cheaper. But if your envelope doesn’t meet their machine-friendly criteria, it gets flagged as non-machinable, which means a real human has to handle it manually. And yes, there’s a fee for that.

What triggers the non-machinable fee?

  • Square envelopes – USPS machines are built for rectangles. So all squares envelopes will cost more, no matter the size and regardless of weight.

  • Too thick or rigid – Using double-thick cardstock or a wax seal? That added firmness will most likely make your envelope too stiff for sorting machines.

(Left to right): Non-machinable square envelope with vintage stamps; non-machinable invitation with layered cards and wax seal.

Non-machinable surcharge = 49¢ per envelope
And yes, that’s on top of your regular stamp and any additional ounce charges.

Let’s say your suite weighs 1.7 oz and includes a wax seal making it rigid. That means your invite will cost:
78¢ (Forever Stamp) + 29¢ (extra ounce) + 49¢ (non-machinable fee) = $1.56

“We love custom invitations. But we love protecting your investment even more.”

Even if your wedding invitation isn’t heavy or square or covered in wax seals, paper thickness alone can send your postage cost way up. If your envelope is over 1/4” thick—even just barely—but still under 3/4 “, the USPS stops treating it like a First-Class letter. It now counts as a large envelope (aka "flat").

The good news?
You’re no longer dealing with that non-machinable surcharge.

The not-so-good news?
Flats have their own pricing, and yep, it’s higher.

Here’s how it breaks down:

  • First ounce = $1.63

  • Each additional ounce (up to 4 oz) = 27¢

So if your wedding suite is thick enough to count as a flat and weighs 2 ounces, you’re looking at:
$1.63 + 27¢ = $1.90 per invite

Or if it weighs 3 ounces, your cost will be:
$1.63 + 27¢ (x2) = $2.17 per invite

Keep in mind, most suites that fall into this category either:

  • Use super luxe card stock or printing methods (like double-thick stock perfect for letterpress)

  • Include extras like belly bands, thick ribbons, fabric wraps, or boxed packaging

Pro tip: Purchase a USPS mail slot guide to test your envelope’s thickness. If it doesn’t slide through the 1/4” slot easily? It’s a flat.

You may have heard people say you should “hand-cancel” your wedding invites. But what does that mean?

Hand-canceling is when a postal worker manually stamps your envelope to mark the postage, instead of it going through the first automated machine that applies a printed barcode. This helps prevent your envelope from getting bent or damaged from this first step.

But! It doesn’t prevent your envelope going through other machines later in the delivery process.

Here’s what else to know:

  • It won’t save you money: You’ll still pay any required surcharges (like extra ounces or non-machinable fees).

  • It’s more about protection: Hand-canceling just gives your envelope a gentler head start.

  • Not every post office will do it: Some are happy to help with a small stack. Others have limits or may ask you to do it yourself.

  • Fees vary: Some post offices offer hand-canceling for free as a courtesy, while others charge a fee in addition to regular postage.

  • It simply looks better: You avoid the harsh automated bar code printed by machines.

Tip: Call ahead or go during off-peak hours. A little patience and politeness go a long way.

And if you’re working with a planner, or stationer (like me!), they can often do this part for you or guide you through the best way to handle it.

White ink on rich, dark envelopes isn’t just stylish, it’s striking. That high-contrast look adds serious drama and gives your suite a polished, editorial finish:

But the post office? Not impressed.

Technically, USPS requires black ink on white or light-colored envelopes. When you flip the contrast, your envelope usually gets flagged as non-machinable and has to be hand-sorted by a human. That slows things down.

Here’s what to expect:

  • Non-machinable surcharge added to your postage

  • Longer delivery times (sometimes weeks more than a regular black-ink-on-white envelope)

  • Ink that can smudge if your printer isn’t using quality white toner

Given all that, we love white ink and we use it often.

Play it smart:

  • Use a printer that offers high-opacity white toner (not all do)

  • Mail at least two weeks earlier than you would otherwise

  • Include the non-machinable surcharge in your postage

  • Make sure the address is legible and crisp to avoid return-to-sender issues

White ink printing can be stunning. Just plan for a little extra time, cost, and care to make sure it arrives the way you intended.

In our opinion, there’s no better embellishment for your envelope than vintage stamps. They add personality, charm, and a touch of nostalgia that’s hard to beat:

But before you start curating your dream stamp combo, here are a few things to keep in mind:

  • They are pricey: Vintage stamps cost double, triple, or more than their face value simply because, well, they’re vintage, and no longer in circulation. The more rare, the higher the price tag.

  • Watch out for fakes: Counterfeit stamps are on the rise. If you see a stamp or sheet selling for face value (or less), it’s too good to be true. USPS won’t honor counterfeit postage, which means your mail could be returned.

  • Buy from trusted sources: Stick to reputable sellers like Mystic Stamp Company, or curated vendors like Little Postage House.

  • Build in extra time: Selecting the right stamps, calculating correct postage, and waiting for delivery can take longer than expected, especially if you’re coordinating sets for multiple envelopes.

  • Order more than you need: Mixing and matching stamps to reach the correct postage can take a few tries. It’s always better to have extra options on hand than to fall short.

  • Hand-canceling is a must: Vintage stamps are more delicate and require special handling. Be sure to ask the post office to hand-cancel your envelopes to avoid machine damage in the first mailing process.

Vintage stamps are a gorgeous detail that absolutely elevates your envelope, but like anything stylish, they take a bit of planning. But totally worth it.

We love custom invitations. But we love protecting your investment even more.

Wedding invitations aren’t just any piece of mail. They’re keepsakes. The first real glimpse of your day. And unfortunately, regular First-Class Mail doesn’t always treat them that way.

The reality is envelopes can get delayed, bent, or even lost. We’re not here to scare you, we just want to set expectations. Recently, we’ve even seen some take over two weeks to arrive within the U.S. and there’s no way to add tracking to First-Class Mail.

Enter USPS Ground Advantage, our go-to recommendation for sending wedding invitations.

Unlike First-Class, Ground Advantage treats your envelope like a parcel. That means you’re allowed to use more protective packaging like rigid mailers, padded envelopes, or even small boxes that helps guard against bending, tearing, or moisture damage during transit.

It also automatically includes tracking, delivers more consistently (typically 2–5 business days), and adds a layer of peace of mind.

This extra protection comes with a higher price tag starting at about $6.80 . However, we’re able to offer our clients commercial pricing, which generally brings that down to around $4.50 to $5 per invitation.

(I totally get it—that’s a big jump from First-Class Mail. But I wouldn’t recommend it unless I truly believed it was the best way to protect what you’ve invested in, both creatively and financially.)

If you’re thinking, “But I still really want to use vintage stamps”?

We don’t blame you, they’re fabulous. And yes, you can still use them with Ground Advantage!

You simply place your beautifully stamped envelope inside the protective mailer. It’ll arrive exactly how you envisioned it: pristine, stylish, and totally on theme. Just keep in mind, you’ll be covering postage twice (the cost of Ground Advantage plus your vintage stamps). But: you don’t need to go overboard on the stamp value since it’s not actually doing the mailing. Just a few will make the statement.

Whether you're sticking with stamps or going the Ground Advantage route, one thing remains the same: mailing wedding invitations takes a little more planning than most people expect.

The upside? You’ve got options—and now you know what they are. From avoiding surprise surcharges to keeping your envelopes safe in transit, you’re already ahead of the game.

And don’t forget to budget for postage, no matter which method you choose. It’s one of the most overlooked parts of stationery planning.

Want to keep this info handy? [Download our Lucasano Mailing Guide], a quick summary you can save for later or send to your partner who swears “it can’t cost that much.”

Now you can mail with confidence. You’ve got this.

Want to Read more? You may also like:

Luke Gasbarro
Next

Pride 365: Meaningful Ways Wedding Vendors Can Be Year-Round Allies