USPS shipping label printing on 4×6 thermal

Click-N-Ship (USPS direct)

USPS's own portal generates a Letter-size PDF with a 4×6 label and a receipt block below. In the print dialog, choose Print label only — USPS gives you that option built in. Or drop it into PDF Crop Buddy's USPS cropper to strip the receipt after the fact.

Pirate Ship

Pirate Ship is native 4×6. Just choose 4×6 PDF when downloading — no cropping needed. If someone shared a Letter-size Pirate Ship label with you, the cropper handles it.

Stamps.com / ShipStation

Both default to Letter but can be switched to 4×6 in preferences. Look for Label format under printer settings and set to 4 × 6 thermal.

eBay & Etsy USPS labels

Both marketplaces resell USPS postage but wrap it in their own PDF layout. Use the eBay or Etsy cropper — presets already target the correct label region.

Common USPS scan problems

• IMpb barcode too small. Caused by printing Letter-size at "Fit to 4×6". Crop first, then print at 100%.
• Thermal fade. Cheap direct-thermal labels fade in a mail truck's UV exposure — use archival rolls for anything staying in transit over 5 days.
• Cut-off return address. Some third-party printers leave a 3mm no-print margin. Enable "shrink to fit printable area" in the driver.

Postage rate for cropped labels

Cropping the label does not change your postage — the barcode and shipment ID stay the same. USPS only cares about barcode readability.