Abstract: A pop-up mailer is constructed from a single sheet of 81/2.times.11 or A4 paper having a weight of at least 20 pounds per 1000 sheet ream, using a non-impact printer. The adhesive for holding panels of the sheet together after they are folded about a fold line is preferably a pressure sensitive non-tacky adhesive (pressure coadhesive). At least two pop-ups are die cut from the sheet of paper on opposite sides of a fold line, and pressure coadhesive is used to hold the pop-ups together so that when the mailer is opened a pop-up appears. Adhesive may be applied around the die cut edges to assist in maintaining the pop-ups within the plane defined by the paper during processing. After die cutting, imaging, applying coadhesive, etc., the sheet is folded about a first fold line and passed through a pressure sealer, and then folded about a second fold line transverse to the first fold line and again passed through a pressure sealer, to produce a final mailer to which postage is applied directly.