I agree that the post office workers apply the rules differently, and that it's worth a little extra postage to avoid problems.
There is one thing that I know for sure, and can pass on this advice -- I have sold hundreds of these James Bond chips, three chips at a time, for years, and I put them in a small regular envelope with no protection other than wrapping them in paper and securing them with clear packing tape and dropping them off in a mail box and NEVER had any trouble! (Note that the chips are inexpensive and rather modern and strong. The mail piece ends up being no more than 1/4 inch thick. With the three James Bond chips, the whole thing weighs two ounces, so I put on this postage: $0.44, $0.20 plus $0.20 surcharge -- first class letter.. I usually write on the mail piece: "first class letter + surcharge.")
Casino Royale poker chips by mfgr for James Bond movie; excellent quality,weight
http://www.ebay.com/itm/160719841677
Robert
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