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I made ZIP boundaries from the TIGER database in 1993. (Giant Delaunay triangulation/ Voronoi diagram. Fun algorithms for dealing with millions of points! Then merge polygons.)

I believe the demand for this was to visualize attributes on a map by coloring polygons, and the dataset was addresses that already had zip codes.

(Please stop coloring polygons by attribute: it gives false impressions because areas are unequal. Instead, use a scale of dot density. Or marker size, which has its own perceptual issues.)

However misguided, coloring zip code polygons gives you things like maps of customer data. But you could just as well geocode each address and assign it to a county or other boundary. (news flash: the geocoding database is derived from the same line data as the ZIP code project.)

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most people dont know that zip codes are specific to the postal service and dont have anything to do with actual municipal government boundaries. the hierarchy of geo boundaries and the ways to locate and communicate within them is way more interesting than one would believe!
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Some 5-digit zip codes represent the PO Boxes at a post office building.

Some zip codes represent a single building. Example 20500 is the White House. The Pentagon is so big it has several zip codes.

https://convene.com/catalyst/office/buildings-new-york-city-...

It used to be that the first 3 digits of a zip code sent that mail to the "main" post office building (the one that has loading docks for like 10-30 tractor trailers on one side of the building). Even if you were mailing a letter to the same zip, it went to that building to be sorted and returned to the local office before delivery. Nowadays, everything goes to central facilities where stuff is scanned and sorted. In Kentucky, almost all mail goes through Louisville.

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A lot of people also don't know that your written address is also disconnected from municipal government boundaries.

The "city" on my address growing up was a CDP[1], and it is now a city that I live 2 miles from rather than the one that I live less than a mile from.

1: https://en.wikipedia.org/wiki/Census-designated_place

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Polygons do have value in some workflows, if used with the appropriate caveats.

And in no instances have I ever run across use cases where these are worth paying any substantial money for. If USPS is going to jump into the fray here, really bad look (and probably net negative revenue for them) to offer as a paid product.

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I know that many people do use ZIP codes for grouping locations, and polygons may be useful for tieing a lat/long to a zipcode if it doesn't have a delivery location. But it's all kind of silly unless you're sorting mail. Also, I'd hate/love to see some of the polygons where delivery boundaries get weird.

Whatever you're grouping is likely better served by some grouping based on geography, not based on delivery routes. You probably wouldn't group by telephone company central office either, unless you're telco related.

We want to group by geography, zip codes are easy and vaguely geographic, lets use that is kind of a valid decision, but it's deeply frustrating :p

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Completely agree on this. Something I have used for a few applications is the DMA (designated market area) boundaries. It's not ideal for everything, but it's very human-focused: If you live just a few miles across a state boundary from a major city, grouping you with the city makes more sense than with anything in your state.

In fact, these were invented by Nielsen, and they determined them just by measuring which city's TV stations are predominantly watched in each county, and assigning each county to one DMA based on that.

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This. The USPS has always said that a ZIP Code was not a geographical area, but a collection of deliverable addresses. So what is this nonsense?
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As someone who did a little geospatial work, I concur. We had banks complain that we didn't have ZIP codes for some ATM locations.

The ATMs never got mail.

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