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The problem is that if you make the cards to sell, you will need at least two envelopes: one for the card itself and then one in which to mail your card and envelope. That's not so hard-- you may even be able to get leftovers at Hallmark stores for not a lot of money.
But your card will not be able to be highly embellished-- if it is rigid, or the thicknesses uneven, or if it is too thick overall, it may get hit as having insufficient postage and sent back to you (or, worse, sent to your buyer with postage due).
I would also be concerned that my card, traveling in a plain envelope, might get damaged. If that happens, you will have an unhappy buyer. Are you prepared to issue refunds if your card is damaged in transit?
I'm thinking that the extra envelope won't be the problem - the embellishments might add a 20-cent surcharge though.
I sold a card once (yeah, only once) through the mail. What I did was I put the card and its envelope inside a plastic bag, and then put that inside a bigger envelope. Then I bent it with my hands to simulate the card being bent by the machines. Also, I wanted to make sure that the entire combination was not too rigid (it needs to be able to be bent a little, without resistance, to lessen the chances of damage). And I slid it in between the gap on my paper cutter to make sure the entire combo was less than 1/4 inches.
Faites l'amour, pas la guerre, ...ou alors, faites les deux : mariez vous !
Cards for troops and kids
I protect my cards by adding an additional layer of card stock or a thin piece of cardboard as a protective layer. I generally mail my card and matching envelope in an A7 envelope 5-1/4" x 7-1/4". This is cheaper than a padded envelope.
Also make sure it is waterproofed. I got a bunch of mail the other day that was waterlogged as we had a big rain/snow storm. I wasn't too upset by having to dry my bills, but wouldn't have had as much success with a card.
Save your drama for your llama.
The shipping is the cost of business.
My cards are placed in clear bags (covering card and envie) to protect against moisture. Single cards are then sent in rigid mailers.
First class postage for 2 and 3 oz. is 1.69 if you buy online using paypal. This will also cover the cost of a tracking number.
Remember, you are responsible for getting your items to your customer in the same condition they bought ihemt. If it is bent, gets wet or gets lost, it is your responsibility.
Putting in your policies that it is the customer's responsibility to buy insurance is not true. I can guarantee you that if the item arrives damaged and they dispute the charges with paypal, you will lose, regardless of any insurance.
I've always thought it was better to be safe than sorry and that means charging more for shipping.