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According to McIntyre, there’s always a significant cost difference per yard between paper weights from, for example, 36 to 70 lbs.; but the cost of a smaller difference (say, 10 lbs.) varies with demand.
To a lesser degree, postal costs may figure into your decision on cover stock weight. Some printers, such as Arandell, allow clients to use their postal calculators to determine whether a change in paper or cover stock weight will affect postage costs for the run. These calculators also are available on the USPS Web site at www.postcalc.usps.gov.
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