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There are two methods for creating the new 'Intelligent Mail Barcode' required for 2009 by the USPS.
USPS Method:

Register with USPS to obtain a user name and pass code so you can download the font. It takes about 2 days to get from them.
Go to http://ribbs.usps.gov/onecodesolution/ and logged in.
Proceeded to download file name : uspsFontsNonAFP-1.3.0-compact.zip
Unzipped then copied it to your Library>Fonts folder(MAC) or WIndows Font folder on your PC.
Opened Acrobat.
Under Fusion Pro tab selected Advance>Load Fonts.
Quit Fusion Pro and Acrobat.
Opened my PDF with the variable data in and inserted the field then
changed the font to USPSIMBCOMPACT or the PC equivalent.
Select font size to 16pt. Previewed it to ensure it will print correctly.
Hope that helps!
When creating the IMB, and your mailing software generates ' F, A, D, and T' characters .
Use the USPS4CB font (from the USPS), set the size to 16 pt and you're done. No rules required or create in FusionPro..
FusionPro Method:
Intelligent Mail Barcode script for users parsing data with mailing software.
First create an 'Empty' Text Rule,i.e.'Create Rules>>New Empty'.
Click the box for 'Treat Return Strings As Tagged Text'.
Give the Rule an identifiable name, which will be selectable in the 'Variable' drop window of the text frame where this
information will appear.
Then paste this script(Make sure the field name matches your data file):

var onecode = Field('Intelligent Mail Barcode'); //Replace 'FATD' with Field('Intelligent Mail Barcode')
onecode = onecode.replace(/F/g,'0'); // replaces all F with 0
onecode = onecode.replace(/A/g,'1'); // replaces all A with 1
onecode = onecode.replace(/T/g,'3'); // replaces all T with 3
onecode = onecode.replace(/D/g,'2'); // replaces all D with 2
return onecode;

Then insert the Rule name into the text variable where the barcode will appear. Apply the 'IDAutomation4State' font.
Barcode

This page lists USPS Intelligent Mail barcode files, Fonts and Encoders, available for download.
Select an entry in the list-box; files matching the criteria are shown.

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NameDateDescription
uspsEncoderAixPower-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for AIX on IBM Power platforms such as RS6000. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderDecoderCalculator-edc.zip2010-04-29edc.exe is a utility designed to facilitate encoding and decoding USPS IMb. It requires Java 1.5 or greater be installed on MS Windows OS'es; 2000, XP, Vista and Windows 7 have been tested.
uspsEncoderHP-UX-PA-RISC-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for HP-UX on HP-PA-RISC platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderHP-UXItanium-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for HP-UX on Itanium platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderLinuxIntel-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for Linux on Intel/AMD x86-32 platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderLinuxIntel64-1.2.0.zip2008-09-30USPS Intelligent Mail barcode Encoder distribution for Linux on Intel/AMD x86-64 platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderLinuxPower-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for Linux on IBM Power platforms such as RS6000. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderMVS-1.2.2.zip2011-09-05USPS Intelligent Mail barcode Encoder distribution for MVS on IBM Mainframe platforms. The distribution includes examples and a standard load-module callable from Assembler, C, COBOL, and PL/I. A jar-file and an example is included for using the Encoder from Java.
uspsEncoderMac-1.2.0.zip2008-05-18USPS ntelligent Mail barcode Encoder distribution for Mac OS X on Intel and on IBM Power platforms such as iMac and MacBook computers. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderMacDesktop-1.3.0.zip2010-12-14USPS Intelligent Mail barcode Encoder distribution for Mac OS X Desktop applications such as MS Excel and Word, and Apple iWork '09 Pages and Numbers. The distribution includes procedures and sample templates for performing a Mail Merge operation using the applications within either MS Office for Mac or Apple iWork '09.
uspsEncoderMsOffice-1.3.1.zip2011-02-15USPS Intelligent Mail barcode Encoder distribution for MS Office 32-bit edition applications such as MS Word, MS Excel and MS Access, running on either 32-bit or 64-bit MS Windows operating systems. The distribution includes procedures and sample templates for performing a Mail Merge operation from MS Excel or MS Access to MS Word.
uspsEncoderMsOffice64-1.3.1.zip2012-03-27USPS Intelligent Mail barcode Encoder distribution for MS Office 64-bit edition applications such as MS Word, MS Excel and MS Access, running on 64-bit MS Windows operating systems. The distribution includes procedures and sample templates for performing a Mail Merge operation from MS Excel or MS Access to MS Word.
uspsEncoderMsWindows-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for MS Windows, 32-bit, on Intel/AMD x86 platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderMsWindows64-1.2.0.zip2008-09-30USPS Intelligent Mail barcode Encoder distribution for MS Windows, 64-bit, on Intel/AMD x86-64 platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderOS400-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for IBM i. IBM i is an operating system used on IBM Power Systems formerly known as System i, iSeries and AS/400 computers. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderSolarisIntel-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for Solaris on Intel/AMD x86 platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderSolarisIntel64-1.2.1.zip2009-09-04USPS Intelligent Mail barcode Encoder distribution for Solaris, 64-bit, on Intel/AMD x86-64 platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderSolarisSPARC-1.2.0.zip2008-05-18USPS Intelligent Mail barcode Encoder distribution for Solaris on SPARC-based platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderSolarisSPARC64-1.2.0.zip2008-09-30USPS Intelligent Mail barcode Encoder distribution for Solaris, 64-bit, on SPARC-64 platforms. C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.
uspsEncoderVSE-1.2.1.zip2011-03-21USPS Intelligent Mail barcode Encoder distribution for VSE on IBM platforms. The distribution includes examples and a standard load-module callable from Assembler, C, COBOL, and PL/I.
uspsEncoderzLinux64-1.2.0.zip2008-09-30USPS Intelligent Mail barcode Encoder distribution for Linux on zSeries systems; other terms used to describe the platform include Linux/390, Linux on zSeries, Linux for zSeries, Linux on System z9, zLinux and z/Linux.

C and Java sample code to call the Encoder along with run-time libraries are included in the distribution.

uspsFontsAFP-1.4.0.zip2008-09-30USPS AFP (Advanced Function Printing) Intelligent Mail barcode fonts are distributed for MVS, VSE and OS/400 print platforms.

There is a Standard (16pt) font and a Compact (14pt) font for each AFP print platform.

Standard (16pt) fonts are USPS compliant when printed at 16pt. Compact (14pt) fonts are USPS compliant when printed at 14pt.

uspsFontsNonAFP-1.4.0.zip2010-04-23USPS non-AFP Intelligent Mail barcode fonts are distributed for the Postscript Type1 (PS1) and Type 3 (PS3), TrueType (TTF), HP-PCL, and Xerox Metacode print platforms.

There is a Standard (16pt) font and a Compact (14pt) font for each print platform.

Scalable Standard fonts are USPS compliant when printed at 16 or 17pt; 16pt is recommended.

Scalable Compact fonts are USPS compliant when printed at 14, 15 or 16pt. Only the barcode string of the scalable 14pt Compact fonts (PS3 or TTF) is less than 3 inches; however, these barcode strings risk non-compliance when printed on imprecise printers.

uspsIMbLicense.txt2009-05-27The USPS IMb software is provided by the United States Postal Service 'as is' and any expressed or implied warranties, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose are disclaimed.

In no event shall the US Postal Service be liable for any direct, indirect, incidental, special, exemplary, or consequential damages (including, but not limited to, procurement of substitute goods or services; loss of use, data, or profits; or business interruption) however caused and on any theory of liability, whether in contract, strict liability, or tort (including negligence or otherwise) arising in any way out of the use of this software, even if advised of the possibility of such damage.

uspsReferenceSetDecoder1.0.0.zip2010-02-04This zip-file includes a set of test cases to facilitate testing of an IMb Decoder algorithm. Three file formats are available, XML, CSV and a text-file. An IMb Decoder algorithm should detect error conditions specific to the IMb Decoder function. The documentation included in the distribution provides the required information to use these test cases.
uspsReferenceSetEncoder1.0.0.zip2010-02-04This zip-file includes a set of test cases for the USPS IMb Encoder. It is available to facilitate development and test of the IMb Encoder and/or custom encoder algorithms. Three file formats are available, XML, CSV and a text-file. Each of these 3-files contains the same 10,000 test cases. Although there is a separate zip-file for the Decoder, these test cases serve also as a source for testing Decoding applications.
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