Frequently Asked Questions

Impact Direct Printing is a print agency for direct mail located in Elk Grove Village, IL, serving the greater Chicago area and clients nationwide. We handle every step of a direct mail campaign: data processing, CASS/PAVE certification, variable data printing, postal optimization, and delivery tracking. Our production handles runs from 5,000 to 5 million pieces on high-speed digital inkjet and web offset presses.

A direct mail campaign has six steps: (1) Data processing — cleaning, deduplicating, and NCOA-updating your mailing list. (2) Design — creating mail-ready artwork with barcodes, indicia, and variable field mapping. (3) Printing — high-speed digital inkjet for personalized pieces or web offset for static high-volume runs. (4) Mail prep — tabbing, folding, inserting, inkjet addressing, tray/sack sorting. (5) Postal optimization — presorting, commingling, and drop-shipping to USPS facilities for maximum discounts. (6) Tracking — Intelligent Mail barcodes provide real-time delivery visibility.

Direct mail costs depend on format, quantity, paper stock, personalization level, and postage class. A standard 6x9 postcard campaign typically ranges from $0.35–$0.85 per piece all-in (print + postage) at volumes of 10,000+. Self-mailers run $0.50–$1.20 per piece. Letter packages in #10 envelopes range $0.75–$1.50 per piece. Impact Direct's PressPass tool provides instant estimates for common formats at impactdirectprinting.com/presspass. Postage alone (after presort optimization) typically runs $0.18–$0.35 per piece for Marketing Mail (formerly Standard Mail).

A self-mailer is a direct mail piece that is its own envelope — a single sheet (or folded sheet) that is printed, folded, tabbed or wafer-sealed shut, and mailed without an outer envelope. Common formats include bi-fold (single fold, tabbed on the open edge), tri-fold (letter-fold, tabbed), and Z-fold. Self-mailers are popular because they cost less than letter packages (no envelope, no inserting labor), have higher open rates than envelopes, and allow full-bleed color on all panels. USPS requires tabbing or wafer seals to meet automation compatibility standards.

EDDM stands for Every Door Direct Mail, a USPS program that lets you mail to every address on selected postal carrier routes without buying a mailing list. You choose routes by ZIP code, and every residential or business address on those routes receives your piece. EDDM is ideal for local businesses targeting specific neighborhoods. The postage rate is approximately $0.223 per piece (as of 2026), making it one of the most cost-effective direct mail methods. Impact Direct handles EDDM campaigns from design through delivery.

A print broker is a company that manages print production on behalf of clients, handling estimating, project management, quality control, and logistics. Impact Direct Printing operates as a print management company with direct access to web offset presses, high-speed digital inkjet, and digital sheetfed equipment. This means we control quality, scheduling, and pricing directly rather than simply reselling from third-party vendors. The advantage of working with a print broker like Impact Direct is a single point of contact for all print formats and production methods, competitive pricing across multiple technologies, and expert guidance on matching your project to the right production method.

Variable data printing (VDP) is a digital printing technique where elements of a printed piece — text, images, QR codes, barcodes, offers — change from one piece to the next based on data in a database or mailing list. Each piece in a print run can be unique while maintaining full production speed. Common applications include personalized direct mail, statement printing, transpromo documents, and targeted marketing campaigns. Impact Direct uses high-speed continuous-feed digital inkjet presses for VDP, which means personalized pieces print at web press speeds with no per-piece cost premium compared to static printing.

The best paper for direct mail depends on the format and production method. For postcards: 100# Gloss Cover or 14pt C1S provides rigidity and a premium feel. For self-mailers: 80# Gloss Text or 70# Offset works well for folding and tabbing. For digital inkjet personalized pieces: inkjet-optimized uncoated stocks deliver the best print quality at the lowest cost — Impact Direct's Bravo paper (50#, 55#, or 60# SCA+++ grade) is engineered specifically for high-speed inkjet production and priced 20–40% below standard market rates. Key considerations: weight (affects postage — stay under letter rate thresholds), coating (gloss for photos, matte/uncoated for readability), and inkjet compatibility if using digital production.

Impact Direct Printing is located at 1101 Arthur Ave, Elk Grove Village, IL 60007, in the Chicago metropolitan area. We serve clients in the greater Chicago area, throughout Illinois, and nationwide. Our central location provides efficient logistics access for USPS drop-shipping to SCFs and NDCs across the country, which means faster delivery times and deeper postal discounts for your direct mail campaigns.

PressPass is Impact Direct Printing's instant online quoting tool, available at impactdirectprinting.com/presspass. You select your print format (postcards, booklets, catalogs, self-mailers, etc.), enter your specifications (quantity, page count, paper stock, finishing options), and receive an estimated price range in under 60 seconds. PressPass is designed to eliminate the typical back-and-forth of print quoting — no phone tag, no waiting for callbacks. For exact pricing on custom or complex projects, our team provides formal quotes within 24 hours.