Cheapest Way to Mail a Package: A 2025 Guide for Small Businesses
Shipping costs can make or break your margins—especially when you’re running a small business or side hustle. Whether you’re sending a one-off gift or shipping ecommerce orders daily, knowing the cheapest way to mail a package can help you save money and deliver on time.
In this guide, we’ll break down the most cost-effective mailing options based on weight, speed, destination, and shipping carriers.
What Affects the Cost of Mailing a Package?
Before jumping into the cheapest methods, it’s important to understand what determines postage cost:
- Package weight and size
- Shipping distance or destination (zones)
- Delivery speed (standard vs. express)
- Carrier used (USPS, UPS, FedEx, DHL, etc.)
- Packaging type (flat-rate box, padded envelope, etc.)
- Additional services (insurance, tracking, signature, etc.)
Cheapest Ways to Mail a Package by Scenario
1. Lightweight Packages Under 1 lb (Domestic)
- Best Option: USPS First-Class Package Service
- Cost Range: $3.50 – $5.50
- Ideal For: Clothing, accessories, books, small gadgets
Pro Tip: Use a poly mailer to reduce weight and dimensional fees.
2. Packages Over 1 lb But Under 5 lbs
- Best Option: USPS Priority Mail (Flat Rate or Cubic pricing)
- Cost Range: $8 – $12 (depending on zone)
- Ideal For: Subscription boxes, mid-sized ecommerce products
3. Heavier Packages (5+ lbs)
- Best Option: UPS Ground or FedEx Ground (zone-dependent)
- Cost Range: $10 – $25+
- Ideal For: Electronics, equipment, bulk items
Use online tools like Pirate Ship or Shippo to compare rates across carriers.
4. International Shipments
- Best Option (Budget): USPS First-Class International (under 4 lbs)
- Best Option (Faster): DHL Express or UPS Worldwide Saver
- Note: Use customs tools and calculate duties to avoid surprise costs.
5. Small Flat Items (Documents, Stickers, Cards)
- Best Option: USPS Large Envelope or First-Class Mail
- Cost Range: $1.20 – $3.50
Cheapest Shipping Carriers Compared (2025)
| Carrier | Strengths | Limitations |
|---|---|---|
| USPS | Best for small, lightweight items | Slower for larger/heavier items |
| UPS | Great for heavy or valuable goods | Higher base costs for small pkgs |
| FedEx | Fast delivery, tracking accuracy | Higher express shipping rates |
| DHL | Excellent international shipping | Limited drop-off locations in US |
Tips to Save Even More on Mailing Costs
- Buy postage online: Platforms like Pirate Ship, Shippo, and EasyPost offer discounted commercial rates.
- Use your own packaging: Dimensional weight pricing can favor custom packaging over flat-rate.
- Batch shipments: Send multiple items in one package when possible.
- Avoid shipping on weekends: Weekends may incur delays or extra fees.
- Use regional carriers: In some U.S. states, local couriers can be cheaper and faster.
USPS Flat Rate vs. Cubic Rate – What’s Cheaper?
| Feature | Flat Rate | Cubic Pricing |
|---|---|---|
| Cost Basis | Box type (S/M/L) fixed price | Volume (cubic feet) + distance |
| Best For | Predictable size/weight shipments | Small, heavy items in small boxes |
| Availability | Predefined USPS boxes only | Any custom box (under 0.5 cubic ft) |
| Flexibility | Limited box options | More packaging freedom |
Verdict: Cubic is cheaper if your box is small and heavy. Flat Rate works for consistency.
Cheapest Way to Mail for Ecommerce Businesses
- Use a shipping platform: Connect Shopify, WooCommerce, or Etsy to tools like ShipStation or Pirate Ship.
- Leverage negotiated rates: Volume discounts apply with most platforms.
- Offer delivery options: Let customers choose between economy and express.
- Automate label printing: Save time and reduce human error.
- Use regional carriers: In some U.S. states, local couriers can be cheaper and faster.
Frequently Asked Questions
1. What is the cheapest way to mail a package under 1 lb?
USPS First-Class Package Service is usually the most affordable option.
2. Is USPS always cheaper than UPS or FedEx?
Not always. USPS is great for small items, but UPS/FedEx may be better for heavier packages.
3. What if my package is oddly shaped?
Dimensional pricing may apply. Use custom-sized boxes and check cubic rates.
4. How can I get shipping discounts?
Use online shipping software or open a business account with carriers.
5. Is it cheaper to print labels at home?
Yes! You save on retail counter pricing and streamline order processing.
Mail Smarter, Not Harder
Shipping doesn’t have to eat into your profits. With the right tools, carriers, and strategies, you can mail packages cheaply without sacrificing reliability.
- Compare rates across USPS, UPS, FedEx, and DHL
- Use weight-based or cubic pricing to your advantage
- Automate your shipping workflows with the right software