Took this into my local USPS location TODAY

Safe-T-Mailer ........................ 37¢
#6 envelope ......................... 5¢
postage stamp (2oz. limit) ...... 77¢
_____________________________
TOTAL ............................ $1.19

Envelope with one chip weighed 0.77 ounces.

At 28.3 grams/ounce, the addition of two 15 gram chips would still weigh less than the two ounce limit.

Cost/chip to mail recap:

1 chip for $1.19/ea
2 chips for 60¢/ea
3 chips for 40¢/ea

OMG ???. I've been using this method for a long time; no problems yet