Error purchasing label

Hi @tomlebioda,

I understand how frustrating it is to reach the very last step of purchasing a USPS label and then run into this message, especially when the rates load correctly but the actual purchase fails. I appreciate you sharing both the screenshot and the logs, this gives a clear picture of what is happening and I am here to walk through this with you.

From the errors you shared, the WooCommerce Shipping server is rejecting the request because a few fields in the package data are not being passed in the expected format. The messages “packages[0] does not match any of the allowed types” and “is_return must be a boolean” point to the label request payload not being structured correctly. This can happen when a package preset is incomplete, when no dimensions are set, or when the order’s shipping address fails USPS validation as seen in the “Address not found” notice.

To move forward, please check the following on your side:

1. Open the order and confirm that the package dimensions and weight are set under the “Package” section. USPS requires valid dimensions, even for flat-rate services.
   Guide: https://woocommerce.com/document/woocommerce-shipping-and-tax/creating-shipping-labels/
2. Double-check the customer’s shipping address for typos or missing information. USPS requires a fully valid address before the label can be purchased.
   You can quickly validate addresses using USPS ZIP Lookup: https://tools.usps.com/zip-code-lookup.htm
3. If presets are being used, try switching to a custom package temporarily to see if the request goes through.
4. If possible, please share your System Status Report using one of these options: https://pastebin.com, https://quickforget.com, or https://gist.github.com so we can confirm there are no conflicts preventing the label from being generated.

Once you send that over, I will take a deeper look and help you get this resolved. Looking forward to your update.

Hi @tembleioda,

Thanks for the update, I appreciate you letting us know that rolling back to version 1.8.11 of the WooCommerce Shipping plugin allowed you to purchase labels again. I understand how frustrating it can be when these errors interrupt your workflow and I want to make sure we get this resolved properly.

Could you confirm whether you performed a full conflict test before rolling back and did not find any plugin or theme conflicts? The conflict test involves disabling all plugins except WooCommerce and switching to a default theme as described in our guide: https://woocommerce.com/document/how-to-test-for-conflicts/

If you have already done this and you are confident the issue only appears in the latest version of the WooCommerce Shipping plugin, please let us know. We will investigate further on our end and submit an internal bug report to our developers. I look forward to hearing from you.

Hi @tomlebioda,

Thanks for the update, I appreciate you sharing more details about what you have tried so far. It is great to hear that you went through a full conflict test, that helps narrow things down and shows you have already taken solid steps toward identifying the source of the issue.

To help us move forward, could you share the outcome of that conflict test in a bit more detail? For example, did the error appear consistently during the test or only under certain conditions? It would also be helpful to know what additional troubleshooting steps you have taken so far besides toggling WooCommerce and other plugins.

When you can, please also share the relevant portion of your WooCommerce Shipping logs that cover the moments when the error occurred, as well as your full System Status Report. You can send both using Pastebin, QuickForget, or Gist so we can review everything clearly.

Once I have those details, I will continue the investigation on my side and help you move this forward.