Paper size affects mailing and postage costs primarily through weight, dimensions, and classification. Larger paper sizes typically weigh more, which can increase postage costs as most postal services charge based on weight categories. Additionally, larger envelopes or packages may exceed standard size limits, leading to higher rates. 
Postal services often categorize mail into standard and non-standard sizes. Standard sizes, like the A-series (A4, A5), usually fit within regular mailing categories, attracting lower postage rates. Non-standard sizes, which may include oversized or unusually shaped items, often incur additional fees due to handling and processing requirements.
The thickness and rigidity of the paper also play a role. Thicker or more rigid paper can push an item into a higher weight category or require it to be mailed as a parcel rather than a letter, increasing costs. 
Moreover, non-machinable items, which cannot be processed by automated sorting machines due to their size or shape, often require manual handling, leading to surcharges. 
In summary, choosing a standard paper size and ensuring the item remains within weight and dimension limits for its category can help minimize mailing and postage costs.