I've been paying $1.30 to $1.50 for one chip... I was told it was because of the thickness (using a padded envelope and a standard #10 envelope with cardboard inside), the chips were considered Priority Parcel.

Today, I shipped in a standard size manilla envelope (half-page size). Inside, I cut a DHL padded envelope to size (The DHL bubble envelopes seems to be flatter than a typical bubble envelope) and put the chip inside the bubble padding (inside a chip sleeve). I was charged for 1 oz. + .17 for "non-machined". Still, 58c is better than $1.30.

I'm sure I will hear from Chuck Mades or Todd Seigel if the packaging doesn't work, but it looked pretty good going out.

I would imagine this would work for several chips, as long as they all laid flat (i.e., not riding up on top of one another and adding to the thickness). Of course, you surpass one ounce. For single chips, this seems to be the way to go so far...