My F-1 OPT EAD was returned to USCIS by the postal service due to an insufficient address, and I have already filed a Non-Delivery of Card request; how long does it typically take for USCIS to process the return and re-mail the card, and are there any additional steps I should take beyond updating my address?
You cannot use your approval notice to start working. You must wait for the physical Employment Authorization Document (EAD) card to arrive.
You did the right thing by filing the non-delivery request quickly. USCIS holds returned cards for 60 business days before destroying them, so acting fast protects your card from being destroyed.
The rules strictly forbid F-1 students on Optional Practical Training (OPT) from starting a job without the physical card in hand. The Form I-797 approval notice does not count as proof of work authorization.
You must wait until you have the physical EAD card and your OPT start date has arrived before you begin your employment. You cannot use alternative proof to satisfy your employer's Form I-9 requirements.
USCIS does automatically destroy returned EAD cards if no action is taken. They keep undeliverable secure documents for 60 business days (12 weeks) after the post office returns them. If they do not find an updated address for you in their system within that window, they destroy the card. If your card is destroyed, you have to file a brand new Form I-765 and pay the filing fee again.
Since you already updated your address and filed an inquiry, USCIS will check their systems and process the return. Official data shows that USCIS successfully re-mails 95 percent of returned cards within 60 business days of receiving them back.
