Vic -- nice video, thanks, I bookmarked it. I'll remember about placing chip high in envelope. Similar to what I suggested about sandwiching between cardboard from cereal box. Could use the corrugated paper in my post above, or use the Starbucks coffee cup holder. Big thing is keeping the mail piece no more than 1/4" thick for letter rate.

Your idea (and mine above) good for sturdy inexpensive casino chips, but not most antique poker chips.

Robt.