Thanks everyone, sounds like there's several good pointers above for saving on shipping. I've just bought a bulk pack of envelopes from Amazon and can use Paypal to save a bit on Postage.
For the Insurance - wow, I guess I had some outdated beliefs. I've been going by the "insure everything over $100" rule for about two decades now. So you guys don't use Insurance at all through USPS? Or is there a dollar amount associated with the cards your sending where you do decide to insure the package or upgrade to Registered Mail? (ie...$500, $1000, etc...)
Much appreciated! I feel like I learned quite a bit from this thread