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If you are mailing inexpensive chips, I honestly don't see any reason that a bubble mailer must be used. I found some hard cardboard postcards at a yard sale (50 for 50 cents). I bend one in half, place the chip inside, tape the cardboard edges together and place it in a standard small business (can't see thru) envelope. I write "Please hand stamp" on it or "non-machinable" and pay 58 cents for it. You must add the extra 17 cents for them to hand stamp it. In the limited time I have been doing this, I've never had anyone say they had postage due or an envelope that got damaged. I have received many chips where someone has used a half an envelope or a folded up piece of paper that works just as well.
If the chip has a larger value and can't be as easily replaced, I do agree a bubble mailer is in order, but for a one or two chip cheap mailer, an envelope with 17 extra cents postage and the chip in something sturdy to prevent damage due to handling, I don't see any reason to pay more. Just my thoughts.
Steve
P.S. I have Postal brochure "Notice 123 - Ratefold, effective July 15, 2007" in my hands. Anyone can get a free copy. It says Large Envelopes (any size between letters and packages) cost .80 for not over 1 oz, .97 for not over 2 oz, 1.14 for not over 3 oz, etc. Letters are - for the same 3 oz stages - .41, .58 and .75 but you must add .17 to that number if you ask for hand stamping. I also now own a cheap food scale that weighs by the ounce that I use to determine my postage. Brand name is Terraillon (it was made in China so please don't let your children lick the paint 
). Hope this helps someone.
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