A whistleblower working inside the United States Postal Service (USPS) has told Congress that a brand-new system for screening mail-in ballots — built in a matter of months, against the advice of the agency’s own staff — is so rushed and untested that it risks mass rejection of legitimate ballots just as the 2026 midterms approach.
The allegations are laid out in an anonymous disclosure filed on Aug. 30 with the office of Senator Richard Blumenthal (D-Connecticut) through the nonprofit legal group Whistleblower Aid. The whistleblower, described as a federal official with direct knowledge of the project, says USPS leadership pushed for a Sept. 1 launch despite internal warnings that the software hadn’t been properly built or tested, and that development continued at points even while federal courts had ordered the work to stop. Blumenthal’s letter demands USPS turn over records and answer detailed questions about the system by early September.
The launch of the new portal is partly in response to a Trump executive order from March 31 directing USPS to write new rules governing how mail-in and absentee ballots move through the postal system. Trump has been adamant the 2020 election was stolen from him, even as recently as last month, as he cited a dubious Census Bureau report to back up his “election fraud” claims.
A 2025 Brookings analysis found that mail-in voter fraud was “very rare,” according to their findings. An additional analysis by American Immigration Council also concluded that the Heritage Foundation’s report on noncitizen voting proved there “is no crisis of noncitizen voting” and that it’s “exceedingly rare.”
The White House’s purported aim is to verify that only eligible, registered voters receive ballots by mail, using unique barcodes tied to state-maintained voter lists. The EO also adds that states that do not comply could lose federal funding. The U.S. Constitution mandates that election laws are under state supervision, which includes the tabulation and tracking of mail-in ballots.
USPS published a proposed rule in June and a final rule on Aug. 26 that, for the first time, gives the Postal Service a gatekeeping role over ballot mail — meaning USPS can now refuse to mail ballot batches that state election officials have already prepared and approved. According to Blumenthal’s letter, USPS has never previously had this kind of authority over how states run their own ballot mail.
USPS has not yet responded publicly to the specific whistleblower allegations. Here’s what the new system is supposed to do, and why the disclosure says it might not work.
How the new system is supposed to work
To carry this out, USPS has been building an entirely new piece of software called the Federal Ballot Mail Portal. Per the disclosure, the process has three parts:
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The Portal itself, where state election officials upload a list of every registered voter getting a mail ballot, along with each ballot’s unique barcode, creating a statewide “Mail-In and Absentee Participation List.”
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A manifest check, where officials separately upload a batch manifest. This is basically an inventory of the specific ballots they’re about to mail into an older USPS bulk-mail system. USPS then automatically checks whether the barcodes in that manifest match the ones already logged in the Portal.
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A physical scan at the post office, where USPS employees scan a sample of the actual ballots in a batch to confirm the physical barcodes match what’s on file, before agreeing to mail the batch at all.
What’s causing the most alarm from lawmakers and critics is that if either check fails, USPS won’t mail the ballots.
The whistleblower says USPS is enforcing what amounts to a zero-tolerance policy. If even a single ballot’s barcode in a batch fails to match or scan properly, the entire batch gets bounced back to the state, the whistleblower alleges.
In action, as the whistleblower describes it, if a state were to bring 10,000 ballots to USPS and just one can’t be verified either cause a voter recently changed their name or moved, USPS would decline to mail the other 9,999 as well. States would then have to pull the whole batch, fix the one ballot, and resubmit the entire manifest to restart the verification process from scratch.
Barcode scanning errors aren’t hypothetical, either. The disclosure cites a 2017 audit by the USPS Office of Inspector General that looked at problems with package-tracking scanners; among its findings, one unspecified issue was tied to roughly one in 20 scans coming back wrong. Apply even a fraction of that error rate to ballot batches instead of packages, and a meaningful number of valid ballots could get swept up in a rejected batch.
There’s also no clear appeals process. The final rule says voters or election officials will be told about “escalation procedures” if they want to challenge a rejection, but doesn’t specify what those procedures actually are — and voters may not find out their ballot was part of a rejected batch until it’s too late to get another one or vote in person.
How this affects the 2026 Midterms
According to the disclosure, USPS didn’t start serious work on the Portal until around mid-June 2026 and was targeting a Sept. 1 launch. The whistleblower says a project of this complexity would normally take nine months to a year, and cites a member of the Postal Regulatory Commission making a similar estimate publicly.
When staff raised concerns about the compressed schedule, one senior official is said to have brushed them off, insisting the launch simply had to go perfectly with no room for error. Additionally, a federal court order blocked the ballot-mail provisions of the executive order on June 25, but the whistleblower alleges that the order was ignored, and work started up again in the days following the ruling.
By the whistleblower’s account, the complete system wasn’t even assembled in a testing environment until the week of Aug. 24 — leaving roughly four working days for customer-facing testing before the planned launch, on a system meant to help run a federal election. Sen. Blumenthal has given USPS until Sept. 4 to answer a list of questions, specifically whether USPS actually paused work as required, who authorized development to continue, and whether any testing has been done to catch false rejections. The senator also gave a Sept. 8 deadline to hand over internal records.
Altogether, the USPS mail portal is one of many avenues the White House is pursuing to change the rules governing mail voting before November’s midterms. On Aug. 24, the Supreme Court’s conservative majority let the administration move forward on the executive order. The majority didn’t rule on whether the order was legal — it said the challenge was premature because the rules hadn’t been finalized yet, reasoning states couldn’t show they’d actually been harmed.
On Capitol Hill, Senate Republicans tried and failed in early August to push through a pared-down version of the SAVE America Act requiring photo ID at the polls, after leadership concluded they didn’t have the votes for the full bill, which would also mandate proof of citizenship to register and roll back mail voting more broadly. That measure has now failed at least six times this year, but GOP leaders say they’ll try again when the Senate reconvenes in this month.
Through these various legal levers, the administration has several routes still open to reshape how — and whether — millions of mail ballots get counted this fall, even without a single bill becoming law.
Source: https://mashable.com/tech/whistleblower-alleges-mail-in-ballot-system-rushed-not-ready
