Barry - think we on the ChipBoard have discussed this before, but whenever I try mailing a chip in an envelope, the clerk bends it around a little. I've been told before that rigid has to be considered a Small Packet (package). I was told at one time, if I wanted to mail as First Class, I would have to use no rigid padding, just maybe a single strip of bubble wrap or plastic, but definitely NOT a Starbucks-type cardboard coffee-cup holder.

I know other sellers have gotten away with this from time to time, as I have received such mailings in good order at my end.

But I'm just repeating what I've been told.

Maybe try an entirely different post office if that is convenient for you? Or give up on the Non-Machineable option which apparently is what the P O would like us all to do!