To make a bigger impact, without increasing the cost of direct mail, we have been using unique folds. The trick is to keep the size within the post office standards and keep the quantity fairly low. Unique folds can be expensive for higher quantities since they generally need to be done by hand. We all know that a lot of direct mail we receive goes directly into the trash without as much as a glance, but if a piece of mail has a unique fold, suddenly the piece has a third dimension, it’s interactive! It is almost guaranteed to have impact.
Foldfactory.com has a great FOLD resource titled 60-second Super-cool FOLD of the WEEK. Have fun folding!