USPS boxes you might not know about (and other tips)

If you’re like me, you might find it really confusing to try to learn how to ship a variety of items to many locations. I’ve run my micro-business (😊) for a few years now, and I have learned several USPS tricks that come in handy when I ship paintings, duckies, and other art. There is certainly more for me to learn about shipping, but these are all tips I wish I could have found years ago.
Sections:
  • Boxes (domestic and international items)
  • International Shipping
  • Regular Envelopes (shipping small items cheaply internationally)
  • Shopify (how I usually calculate shipping nowadays)

Note: I calculated all the rates in here on 4 November 2023, so they are subject to change as you read this blog post at a later time.

 

Boxes

USPS has “flat rate” and non “flat rate” shipping options. Flat rate boxes are excellent for shipping heavy items, because the shipping price is the same no matter what you put in there or the distance it must travel. However, if you make items that don’t fit in USPS flat rate boxes, there are so many great options for boxes that aren’t readily apparent on the USPS website. (While you can go buy your own boxes for shipping, USPS also offers free boxes if you’re shipping with them, and that’s what I prefer to use.) Some of my favorite non-flat-rate boxes that I didn’t know about when I started:
  • USPS Priority Mail® Box 4: This box measures about 7” x 7” x 6”, so it can hold pretty much any duck or set of ducks I ship (or, small paintings back when I shipped canvas art). It has room for packaging material, easily fits postcards in addition to small packages, and is easy to carry. 
  • USPS Priority Mail® Box 1096L: This box measures about 9” x 6” x 2” and it’s the perfect alternative when I have something that has a dimension only SLIGHTLY larger than would fit in a Small Flat Rate Box.
  • USPS Priority Mail® Shoebox: This is a bigger box (about 14” x 5” x 7”) and interestingly it can be less expensive to ship than a medium flat rate box (as you can see in the table below)!

Priority Mail® Box - 4 Priority Mail® Box - 1096L Priority Mail® Shoe Box

I have used all these boxes to great success! You can get any of them at the post office. If you don’t have a post office nearby, you can use the links I included above to order any USPS boxes (flat rate or non flat rate) to your home for $0! They come in packs of 10 or 25. Whenever I notice I am running low on USPS Box 4, I just go to the USPS website and order a new pack of them, which is free and arrives in about a week.

Shipping cost examples for these boxes:
(0.5 lbs here means the item, the box, all the packaging material, so make sure you weigh it all together)

Box type
Box size (rounded down to nearest inch)
Cost to mail 0.5 lb from Seattle to Boston in USD
Small Flat Rate
8” x 5” x 1”
$10.20
Box 4
7” x 7” x 6”
$12.55
1096L
9” x 6” x 2”
$12.55
Shoebox
14” x 5” x 7”
$12.55
Medium Flat Rate
13" x 11" x 3" or
11" x 8" x 5"
(there are two sizes)
$17.10
Large Flat Rate
12” x 12" x 6"
$22.80

And remember: only use a Flat Rate box if you’re choosing Flat Rate postage.

As for timing of your package’s arrival: the USPS has a handy map of city hubs that tend to have faster shipping for Priority Mail. Enter your origin ZIP code and it will show you!

USPS map of shipping times across the US

My biggest secret for finding economical and efficient USPS boxes is: go to a USPS location when they’re not super busy and ask a USPS employee for help! They are so friendly, kind, and have an encyclopedic knowledge of box types. Bring both your item and your preferred packaging materials so that they can help you figure out what fits and costs the least.
As an example: I used to ship small ducks in a 3” x 3” x 3” Uline box, until a kind person at USPS let me know that tiny boxes are liable to get lost in USPS facilities; their machines are not built to handle any rectangular/square packages without a dimension over 5”. It’s something I never would have learned without talking to them!

3 x 3 x 3" Corrugated Boxes S-13287


International Shipping

International shipping seemed endlessly confusing to me when I first tried to figure it out. I can’t say I know all the details yet, but some things that make it easier for me are:
  • Fill out the customs declaration form online, not by hand on paper. It is so much simpler to understand when the USPS page guides you through the form. Use the USPS Click-N-Ship website (which now gives you commercial rates) if you don’t already pay for a website like Shopify with a direct USPS integration. Once you enter a foreign address, the customs declaration forms will show and they are simple to fill out.

    Unfilled customs form on the USPS site   Filled customs form on the USPS site
  • You do not have to use boxes to ship internationally: you can use a padded envelope with something rigid (like cardboard or a box) INSIDE the envelope- a padded flat rate envelope can be cheaper than a small flat rate box if it fits and safely packages your item (see table below). I learned this trick from a USPS employee! 😊
  • Use USPS First-Class Package International Service instead of USPS Priority Mail International: I thought international shipping was always going to be $60+ USD and couldn’t understand how everyone was running their businesses with those prices. Turns out, people are shipping outside the US with USPS First-Class Package International Service, not USPS Priority Mail International- it’s a slower mail service, but still tracked.
    Example:
    Box type
    First-Class Package International Service® Choose Your Own Box
    $20.35
    Priority Mail International® Padded Flat Rate Envelope (12" x 9")
    $42.90
    Priority Mail International® Small Flat Rate Box
    $44.50
    Priority Mail International® Choose Your Own Box
    $60.20

    To figure out what prices are for First-Class Package International Service, you can also use the tables that the USPS has published.
    Pick the country here and get its “price group”, and then take that price group and your total package weight over to the price table here.

    USPS country shipping rules
    Shipping price table

    When I ship art internationally, I either use a box or a padded envelope with a box in it. Make sure you read the instructions on the postage you choose: for example, there are minimum sizes for boxes/ padded envelopes.

    USPS package size rules


Regular envelopes

I recently learned that I can ship are internationally with just a regular card stock envelope, if it’s less than 3/4” wide and is a somewhat consistent thickness throughout. I use card stock envelopes because it provides another layer of protection to my art, and also importantly, helps even out the envelope width so that it can correctly pass through the sorting machines at the USPS (that’s where that 3/4” uniform width requirement comes from).

Uline Stayflats
The envelopes I use are large because they kind of have to be- the USPS requirements for international letters are that a regular letter in a regular envelope cannot exceed 1/4” wide (which doesn’t fit my art), and the requirements for the next largest size (a “Retail Large Envelope”) is that the envelope dimensions are at least ~11” x 6” and not exceeding 3/4” wide… which is kinda big. And you can’t use the free USPS Flat Rate envelopes because this isn’t a Flat Rate package- you’ll have to source envelopes elsewhere, like at Uline. The USPS requirements for the Retail Large Envelopes are here:

USPS large envelope rules

The prices are here in this table below- whatever the price is, you just buy regular stamps to stick to the envelope to cover the cost. As an example, shipping a 3.8oz stiff envelope to Canada is $3.82, but you might also be paying for your own stiff envelope (and you might not have the exact change in stamps unless you buy all stamp denominations or make your own stamps with Stamps.com).

Stamps prices

So, if it fits in the stiff envelope: it’s not tracked, you’ll have no idea where it is or whether it got there, but to go from the US to Canada it’s only $3.82 (plus your packaging costs) instead of $15.75.


Shopify

I learned all this stuff but end up (usually) using Shopify to calculate my rates for me now. I tell my Shopify instance what box types I use, and Shopify has discounted USPS rates that they provide directly to my customers. Shopify is very easy, but not cheap. I didn’t switch to Shopify until the annual price was worth it for my sales.

Shopify doesn’t currently (to my knowledge) support pairing a specific box with a specific shop item, so sometimes the shipping rates it guesses based on item weight are a little too low for what I pay. Also, Shopify doesn’t have a way to let you buy the untracked mail types (like the envelope + stamps method above). It’s not enough to dissuade me from using the enormous simplicity of the rest of Shopify, but it’s still good to know how mail works in those times when I can’t use Shopify’s system.


Conclusion

I hope this blog post gave you some ideas for shipping your art in a better or cheaper way. Thank you for reading!

Let me know if you have any feedback by messaging me on Instagram (@jackies.glass) or emailing me at jackie@jackielovenart.com.