I don't know if this was mentioned here, but the Post Office has come out with a new, cheaper, small flat rate Priority Mail box that might be useful for mailing a large number of chips. (Of course, if the parcel weighs no more than 13 ounces, you are better off sending it first class parcel/package rate.)

Up to now there have been three relatively large and expensive flat rate priority mail boxes -- the retail postage being $10.35, $10.35 and $13.95. There is now the new 4th BOX -- 5-3/8" x 8-5/8" x 1-5/8" that costs only $4.95 retail in postage. That is about the cost of the current priority mail flat rate ENVELOPE. (The on-line rate of postage is a little less than the retail rate.) The boxes themselves, of course, are free from the Post Office.

You can read the USPS announcement here:
http://www.usps.com/communications/newsroom/2009/pr09_003.htm?from=home_newsandannounce&page=NewPriorityBox

Click here to view all of the Post Office's flat rate boxes and envelopes. You can click on the individual products to get more details and the rates:
http://shop.usps.com/webapp/wcs/stores/servlet/ProductCategoryDisplay?beginIndex=0&pageSize=10000&langId=-1&storeId=10001&catalogId=10152&categoryId=13359

Here is part of the USPS announcement:

"WASHINGTON — The U.S. Postal Service (USPS) is launching a new, smaller Priority Mail Flat Rate Box, giving customers another choice in packaging to ship anywhere in the United States for one price, regardless of weight or destination.

The Priority Mail Small Flat Rate Box measures 8-5/8 x 5-3/8 x 1-5/8 inches — about the same size and shape as three stacked DVD cases. The smaller sized box is perfect for jewelry, electronics, event tickets, or other small items that need expedited shipping.

“Customers will find this new sized box a great addition to our line of flat-rate packaging,” said Gary Reblin, vice president of Expedited Shipping. “If an item is too thick for a flat-rate envelope but too small to fill a larger flat-rate box, this is an ideal choice. Customers get quick and easy shipping without having to use a box larger than needed. It’s the perfect combination of size, speed and price.”

Like all USPS flat-rate boxes and envelopes, the new box is available free of charge and also can be used for international shipping.

It will have a retail price of $4.95 effective Jan. 18 — one price, regardless of weight, up to 70 lbs. for U.S. addresses. The international price, for up to 4 lbs., will be just $10.95 to Canada or Mexico and $12.95 to all other countries, with savings of 5 percent for customers who ship online. Online prices also are lower for shipping to U.S. addresses. The online price will be $4.80, and for large volume mailers who qualify for USPS Commercial Plus pricing, the price will be $4.75."

Robert