Yes, you may send the folded over piece. I would tri fold it like you said. I have seen some that were just folded over once and they were too thin to mail or required a surcharge. It must be at least .007" thick to mail, for pieces more than 4 1/4" x 6" it must be .009" or it will require a non machinable surcharge of $.17. (see non machinable criteria in link provided)
Abnormal shapes, no, unless they are part of a mailing that is called Customized Market Mail. For that kind of mailpiece you must have a permit to mail those and they must be part of a mailing of at least 200 identical pieces, a lot of other rules apply to the abnormal piece also but I will spare you the details.
All letter mail must be at least 3 1/2" x 5" and no more than 6 1/8" x 11 1/2" and no more than 1/4" thick and must be rectangular in shape. Square pieces require additional $.17 postage. Anything smaller than 3 1/2' X 5" is not mailable. Anything over 6 1/8" X 11 1/2" or 1/4" thick is considered a flat and goes at a higher rate of postage. For your rate of postage your piece folded over 3 times that wieghs 1 ounce of less would be $.41. Hope this helps. If you have any more questions e-mail me.
See my answer to your other question - basically the same with a small additionHomemade cards and envelopes?
You should be fine to fold a regular size piece of paper into thirds and just mail that without an envelope. I've seen it done. (In fact, I think we sent out bridal shower invitations that way once and it worked fine.) Most other pieces that you suggested would probably be okay too, but the best way to know for sure is to take them to the post office and ask.
You should be able to buy envelopes at a craft store if you want to do that rather than make your own.Homemade cards and envelopes?
if you keep to a fairly standard size envelope (around A6) which is a quarter fold card then you should be okay.
free printable cards and matching envelopes are available at
http://www.canon.com/c-park/
write your own
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