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HANDMADE INVITATIONS AND FINE STATIONERY
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The Wrap on Invitations
Envelopes - Postage
US Postal Service Information for "Letter Size" Envelopes
Dimension Minimum 
Maximum
MaximumHeight 3-1/2 inches 6-1/8 inches
Length 5 inches 11-1/2 inches
Thickness 0.007 inch 1/4 inch
Any item smaller than the minimum dimensions is not mailable.
For larger items, see large envelopes or packages (link to US Postal Service below).
For envelopes, length is the dimension parallel to the address.
Letters that meet one or more of the nonmachinable characteristics below are subject to the nonmachinable surcharge.
For items over 3.5 ounces, see large envelope or package prices.
(Currently as of Nov, 2009 the nonmachinable surcharge is an additional 20 cents)
• It is a square letter
It is a square letter• It is too rigid – does not bend easily
It is too rigid – does not bend easily• It has clasps, string, buttons, or similar closure devices
It has clasps, string, buttons, or similar closure devices• It has an address parallel to the shorter dimension of the letter
It has an address parallel to the shorter dimension of the letter• It contains items such as pens that cause the surface to be uneven
It contains items such as pens that cause the surface to be uneven• The length divided by height is less than 1.3 or more than 2.5
The length divided by height is less than 1.3 or more than 2.5Square Envelope
The minimum size for a square envelope is 5 x 5 inches, maximum is 6-1/8" for letter size charges.
Taken from:
http://postcalc.usps.gov/PopUps/pop_up13.htm
It is a good idea to take a fully assembled envelope containing all the pieces that will be included with your invitation to your post office and have them calculate the exact postage. Postal regulations and prices change at least once a year. The changes sometimes involve envelope categories and sizes that affect the cost of postage.
Here is a link to the US Postal Service website postage calculator for more details:
Response Cards
Please note that other countries may require a different minimum mailable envelope size that is slightly larger than the U.S. minimum requirement. Normally this larger minimum envelope size is: 5-1/2 inches long x 3-1/2 inches high
Reference for other countries requirements:
Index of Countries and Localities
The Wrap on Invitations > Envelopes - Postage
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