I had to mail out 3 singles once. I used the 3 piece cardboard sandwich. Cut out a spot for the chip in one piece, put cardboard on each side of it, tape the 3 pieces together, place on flat rate bubble mailer. Too easy
I recently took a chance at sending a single chip via a plain white envelope and it showed up with the entire side of the envelope ripped open and nothing inside. It was protected and taped down.
If it's for a transaction and not replaceable, ship in a plain envelope at your own risk. Otherwise it's worth the $5 in a padded mailer to make sure it gets there.
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