I present here the best, most economical way --IMHO-- to send chips through the mail if:
(1) the chips are sturdy and relatively inexpensive (that is, you are not too concerned about cushioning the chips).
(2) the total weight of the chips and envelope is no more than 3.5 ounces (so you can use the first class "letter" rate).
(3) you have a relatively low volume of outgoing chip mail. (If you are constantly sending chips through the mail, use corrugated paper or Cro-nel, to save time.)

To get the post office "letter" rate (the cheapest way to send anything), the mail piece must be no more than 1/4 inch thick and must weigh no more than 3.5 ounces. A bubble wrap mailer will not work, often, for "letter" rate pieces. Usually the bubble wrap mail piece will be over 1/4 inch. Many post offices automatically disallow such pieces as eligible for "letter" rate.

One nice thing about the "letter" rate is that generally so long as the mail piece is no more than 3.5 ounces and 1/4" thick, it won't be bumped up to a higher rate class (like to a large envelope or parcel rate class) even if it is found to be non-machinable. If the "letter" rate piece is too rigid or uneven, you merely pay a $0.17 non-machinable surcharge.

Back to the purpose of this post. I send up to a few chips in a regular, ordinary envelope. I wrap the chips end-to-end (not overlapping) in paper or --better yet-- tape them between cereal box-type cardboard. I tape this little package of chips to a regular 8-1/2 x 11" page of paper. I fold the page in thirds and tape the the whole thing to the inside of the envelope near the flap. Two things worth investing time and money in are: a heavy duty tape dispenser and a cardboard template with 1/4" and 3/4" slits in it for seeing if you have the correct thicknesses for first class letters (1/4") and first class parcels (3/4"). (To get Delivery Confirmation, a first class "parcel" must be over 3/4".) See the picture below.

By sending 1, 2 or 3 chips via "letter" rate, the savings are considerable -- over 50 cents. That adds up over time if you are a busy chip trader/seller.

Let's say you are mailing three chips that weigh a little over 2 ounces. So you are paying for three ounces of postage (you must round up). There are three ways to send them first class mail:
¶ "letter" (not over 1/4 inch thick) rate for 3 ounces is $0.75. ($0.92 with the surcharge --see below).
¶ "large envelope" (not over 3/4 inch thick) rate for 3 ounces is $1.14
¶ "parcel" rate for 3 ounces is $1.47.

Now, sending it letter rate, the letter is probably non-machinable because it is rigid, uneven, etc. (see http://pe.usps.com/text/dmm300/101.htm#wp1039555+ ). So if a "letter" is non-machinable, you pay a 17-cent surcharge, which brings the total postage cost to $0.92 (because $0.75 + $0.17 = $0.92). Now, you might think $0.92 isn't much different than $1.14, so why not send it as a "large envelope"? The answer is that even if you get the letter to be under 3/4 inch thick, the "large envelopes" (also known as "flats") must be flexible, uniformly thick, etc. And if the envelopes have these problems ( too rigid or uneven), you DON'T get to pay a 17-cent surcharge. Rather, you are bumped up to the "parcel" category where you pay $1.47 for the 3-ounce thing. The difference between sending the three chips via "letter" rate ($0.92) and "parcel" rate ($1.47) is considerable -- $0.55.

Robert

P.S. I made this Guide for eBay -- "Introduction to Printing PayPal Shipping/Postage Labels." It contains a lot of information and suggestions about the Post Office's classes of First Class mail, insurance, Delivery Confirmation, etc. You get to it by clicking this link:
http://reviews.ebay.com/Introduction-to-printing-shipping-labels-and-postage_W0QQugidZ10000000004429200
If you find it helpful, vote "YES" at the bottom of that page. Thanks.