Cut up bubble mailers so that they fit inside a standard business envelope.
Put the chip in a 2x2 and into the cut up bubble mailer and tape shut so nothing moves around.
Put the bubble mailer in the standard business envelope.
Seal the envelope and then put clear packing tape the length of the envelope over the seal.

I can mail that with the postage for the a standard business letter plus 20¢ because the envelope is little thick.
You get the protection of a bubble mailer at the cost of a standard business letter plus 20¢.
Never had a broken chip or postage due.