I use Pirateship.com. I just put in 3oz padded envelope and it is 3.86 plus the Holiday surcharge of an additional 40 cents. 5oz is 4.15 plus the 40 cents surcharge.
Barry

Thanks, I need to look into that, and I missed the Holiday Surcharge on my last two envelopes mailed. Now I wonder what will happen? And that means, yes I need to look into Pirateship as well.

Just trying to find a way to mail my cheap chips, so a buyer will get a fair deal and not have to pay more for shipping than what the chips(s) are worth. How else can someone list a $1 WI chip that's worth maybe $2, when the shipping is over $3?

The butterfly forever stamps are a great answer. While there were created for wedding invitations and special mailing, they are the answer to mailing, 1-2-3-4 chips. Under 3.5oz

The square format of the stamp was developed in collaboration with the greeting card industry specifically for oversized or square envelopes. These envelopes cannot pass through the automated Postal Service processing system and have to be hand-cancelled. The envelopes are charged a non-machineable surcharge even if they weigh less than 1 ounce.

I managed to find a pack of the Blue 68c and the California Dogface butterfly 70¢ for under the original value, and because they are forever, they are a savings. The current value is 88 cents. (thanks to all the help on the forum!)

If your envelope is more than the standard aspect ratio of machinable letters, i.e., if its length dividend by height is more than 2.5.
If the letter or envelope is rigid or doesn’t bend easily.
If your envelope or letter is square.
If an envelope or letter contains items like keys, pins, buttons, or any other related product that adds uneven thickness.
If the envelope has an address that is parallel to the shorter dimensions of the letter.

#2 and #4 could apply to a casino chip. The way I create the small flat, it is under 1/4" thick.