Sewing Tips

“How do I send masks?”

My last post was about where to send masks. But do you know HOW to send them….without making a trip to the post office?

(Clue: you can NOT send a mask as a “letter”).


From what I hear in the many sewing groups on social media, most mask-makers just want to find the easiest, affordable way to ship out masks…without leaving the house. The United States Postal Service (USPS) doesn’t necessarily make that so simple. There are many rules and regulations within the USPS, you can often get conflicting advice at different post office counters, the website is somewhat confusing, and it’s easy to make mistakes and choose the incorrect postal CATEGORY (size and shape) ….which can lead you to pay the incorrect postage RATE.….or even have your shipments returned. Some makers say the counter clerk advised them it’s okay to just use a single stamp…others were told that they must pay Priority rates.

For many mask-makers, shipping is the most expensive aspect of volunteering. I’ve spent well over $100 over the past month shipping masks. But I have the advantage of lots of experience: over the years, I’ve shipped over 2,000 packages from home for my shops on Etsy and Ebay. I’ll share with you what I’ve learned.


You’re probably familiar with the basic postal RATES, which determine speed of delivery:

  • FIRST CLASS: 2 to 5 days delivery
  • PRIORITY MAIL: 1 to 2 days delivery
  • EXPRESS MAIL: overnight delivery

You may not be as familiar with postal CATEGORIES, which are determined by the thickness, which in turn determines processing….LETTERS and FLATS are sorted mechanically with high-speed zipcode readers, PARCELS are sorted by hand so that costs more:

  • LETTER (under 1/4″ thick)
  • FLAT (over 1/4″ thick but under 3/4″ thick)
  • PARCEL (over 3/4″ thick)

Here’s a further explanation from the United States Postal Office:


What happens when you combine the postal CATEGORIES together with the postal RATES? You can look up any combination on Here’s what it costs to send something from the east coast to the west coast, by weight (this is simplified to exclude specialty rates like regional boxes etc). Let’s assume 3 scenarios:

  • 2 oz: sending a couple of masks to a friend
  • 8 oz: sending a small pile of masks to a doctor’s office
  • 16 oz: sending a larger quantity to a hospital

Let’s simplify: drop Express, way too expensive. For anything under 14 oz, drop Priority, also expensive for saving 1 day in delivery. But for over 14 oz you can’t use First Class so you must use Priority:

Notice the price savings if you could use LETTER or FLAT instead of PARCEL for lightweight items? However, you cannot send a mask out as a LETTER, since it is over 1/4″ thick. A letter envelope is meant for a paper letter, not lumpy merchandise. Letter envelopes get sorted through rapid-feed machinery (check out this video: I hear people online say they put a mask in a letter envelope, stick on 2 stamps, and it’s fine. But it can seriously jam the sorting machines, can get torn up, can be forwarded with postage due, or could come back to you.

So let’s rule out the LETTER category for sending merchandise:

Sad because you wanted to use stamps and avoid going to the post office? You can still use stamps for the FLATS category: 1/4″ to 3/4″ thick, flexible but not lumpy. You can use a cardboard mailer envelope or padded mailer to even out the bumps. Both are readily available at office supply stores (Staples) or big box stores (Amazon). Why the USPS concern over “lumpiness”? Remember FLATS go through automated sorting machinery, just like LETTERS.


Now you’ve got your options narrowed down:

  • 2 oz (a few masks): FLAT
  • 8 oz (a dozen or so masks): can’t squeeze that small therefore PARCEL
  • 16 oz (a whole lot of masks): definitely PARCEL


Look at a real life example. I have a few masks to send to my sister. Together they weigh 2.2 ounces (you must round up , not down):

I have these packaging choices:

Left to right:

  • cardboard mailer
  • padded mailer
  • clasped document envelope
  • letter envelope
  • plastic mailer

If I use the plastic mailer the shipment automatically becomes a PARCEL because it cannot go through the automatic sorting machines. I could choose to use it, but postage will cost more and I can’t use stamps:

I can’t use an envelope because of lumpiness and thickness. Even a single mask is over 1/4″ thick and too lumpy for the rapid-speed auto-sorting machinery:

The clasped document envelop is studier, but still lumpy. The padded envelope is a good choice because it smooths out the lumpiness. Even 3 masks inside can be classified as a FLAT since it’s under 3/4″ thick, and it can take stamps:

Or, I can use a cardboard mailer because it’s under 3/4″ and flattens out the lumps. All set to go out BUT keep in mind that stamps have no “tracking” service.


What about PARCELS? If your mask package is thicker than 3/4″, then according to the USPS online calculator, it automatically moves into the PARCEL category.

  • If it’s under 14 ounces, it can still be sent by FIRST CLASS rates.
  • If it’s over 14 ounces it moves up to PRIORITY rates.

A “parcel” cannot be shipped with stamps. Have you noticed that the street-corner mail boxes no longer have the pull-down opening? They’re being replaced with rigid slots that allow LETTERS or FLATS but not PARCELS. Parcels must go either to the post office counter for printing a postal label, or be picked up by your letter carrier. If you try to send a parcel with stamps, it could come back to you with one of these messages:

You can purchase non-stamp postage labels from your home computer through several online sites: does not allow printing First Class rate postage (only Priority rate or Express rate) but the others do. Probably 90% of my mail goes out FIRST CLASS rate/ PARCEL category, using postage purchased online, shipped in a very inexpensive poly-mailer.

(Once it’s going out as a PARCEL, it can be all sorts of lumpy! That’s because it’s not going through a letter-sorting machine.)


I often hear that people are reluctant to use online shipping services, but they have improved so much over the past few years and are really easy to sign up for and use. I would not recommend for personal use as it requires a monthly fee. My daughter’s favorite is Pirateship. My favorite is Paypal: it is quick and simple to open an account and link payments to your credit card. From there you just fill in the prompts, preview your shipping label, and print on any home printer.

For example, today I’m sending out these masks to a nurse in New York. They can’t be squashed into a FLAT, they must ship as a PARCEL. First I check the weight:


Log into Paypal Shipping, enter the name and address, fill in the prompts for package weight and size, and the system will automatically calculate shipping and let you choose from the possible options:

You can pay the USPS for your label online through your Paypal account \, and print it to any home printer:

You can then go into and schedule a free pick-up.


PS: One more thing to consider….another reason to NOT try gaming the system by mailing masks as “letters”:

I hope this helps clear up some of the confusion about shipping from home. Stay safe!

PS: If you still think you can use a stamp, please watch this:

Happy sewing, Janet


  • Marsha

    Fortunately, my local post office has a self-service machine in the lobby area that’s open 24-hours. I’ve started sending my parcels very early in the morning before the full service area opens. I disinfect the surfaces I’ll be touching before starting, and I wear a mask. I’m a high school mathematics teacher, and I’m usually sending materials to those students who have limited internet service. So far, I haven’t had a parcel returned.

  • Linda G Katz

    This is EXACTLY the information I needed. Came to this via a Google search “how should I ship masks.” Thank you so much for this clear, informative and helpful explanation of the options and costs!

  • Kathryn

    Today I sent out 2 greeting cards in a cardboard/ridgid mailer and sent it as a flat. It was 6 x 8 and 2 oz. I was then worried that I didn’t purchase enough postage which lead me to this article. It seems I may be ok. I’m really trying to figure out for sure because I send so many out and just switched to the ridgid mailers instead of regular envelopes.

  • Susan Bernstein

    This information, particularly about how to ship masks, is just spectacularly clear and helpful. I’ve been lost in postal rate calculating for years. For example, I thought “Priority” meant my item would get priority over other mail…but if EVERY item goes out priority, haha…
    Thankyou for solving the weight and category puzzle and making a clear decision tree. Also, thanks for explaining online shopping through versus by a seller.


    The Post Office told me that a rigid 6×9 envelope was considered a parcel… ugh. $4.50 for 2 masks.
    Do you have any info about that? I see you use cardboard mailer, that’s basically what I had.

  • Sandy Durso

    Your info is helpful – yet I am not 100% clear on the best way to mail 1-2 masks, as I am doing that for fittings.

    With the PayPal route you suggested – are you logging into USPS or Paypal? I am not finding it either way.

    Thanks Sandy in Raleigh NC

  • Rebecca

    Thank you so much, this is so helpful!
    Quick question though…why would the plastic mailer automatically be a parcel vs a flat? Because it’s so floppy? I have padded envelopes that are plastic on the outside. Could I still send those as a flat? Mailing a few masks and a scrub cap.

  • Luann

    Janet, thank you SO much for posting this invaluable information! My husband and I are both thrilled with how well this worked and how much it saved us in postage. I have been making and shipping face masks for family and friends (160+ at this point), and I only wish I had found your tips sooner! I will be pouring over your blog, instagram, and Pinterest information! Thank you, again!

  • Phineas

    Your article was through and informative. USPS was a bit of a mystery to me and this cleared things up beautifully. Thank you so very much for sharing all your time, research, and experience! I’m looking forward to being able to send masks out to family, friends and organizations requesting donations.

  • Nikkiq

    Thank you for taking the time to share your knowledge. I found this information very helpful and it relieved a lot of the stress I was feeling about shipping my product.

  • Cindy

    Thank you so much for this explanation! This is much clearer than the usps website. Wish I had seen it before I got to the post office and had to pay parcel rates for sending 2 masks.

  • Aria

    Hi! This is such great information. But there’s a lot of it and we are brand new at it. My daughter is trying to raise money for a school history trip so she is making masks. We went to go mail one mask yesterday. It was in an envelope with a forever stamp. The post office told us we had to mail it as a package which would cost over $4. She’s only selling the mask for $5. This is not going to work. We obviously need to up the price, but we really need a cheaper way to mail it. Based on what you have written, this is what I’m thinking about doing. Put the mask in a bubble mailer and mail at the flat rate. How many masks do you think i could get away with in a bubble mailer? And what size of bubble mailer are you talking about? The one that is the size of a half sheet of paper? If i do a bubble mailer do i still need to add bulk to one side of the envelope so it will match the height of the side with the mask? Thanks!

  • [email protected]

    Hi Aria! Yes there’s a lot of information (based on many hours of research plus many years of shipping experience) but it’s all there for a reason. For example when you say you plan to “mail at the flat rate”, you may be confusing “Rate” with “Category”. The “Rate” determines the delivery speed (First Class Rate, Priority Class Rate, Express Class Rate). I think you are referring to Flat Category, shipped at First Class Rate, correct? It’s important to have your information clear when going to visit the post office, because often the counter staff is trained to push you into the most commonly used Category, which is a Parcel/Package. And yes, a small Parcel/Package category going First Class Rate will cost around $4 (depending on zip codes). You may want to print out the regulations for the Flat Category from the USPS site and take it with you.

    And I know you already think I’ve given a lot of information to digest BUT…if you go to the post office and ask to ship “Flat Rate” ….they may push you into buying a completely different product which is a Priority Rate box automatically weighed for you at VERY high cost (a tiny little “Small Flat Rate” box the size to fit a couple of masks is $7.95). So again, you do NOT want “Flat Rate”, you want First Class Rate, Flat Category.

    As for how many masks you can put into a flat mailer: as many as you want, so that the thickness is between 1/4″ and 3/4″, with the thickness not varying more than 1/4″(you can always stick in a styrofoam packing peanut to even things out). The size of mailer you buy is going to depend on your business plans: a half-letter-size mailer can accommodate 1 to 3 masks, a larger mailer can fit many more.

    Mailing a single mask is only going to be worth it if you charge extra for postage, or raise the price to include postage fees. Even if your daughter is using donated fabric, she still will need elastic, thread, interfacing, and packaging materials. Have her do a quick search online to see how much people are paying for handmade masks. Mine are $18 on Etsy and I get many repeat customers…and I’ve seen special masks selling for over $100 each!

  • [email protected]

    Yup, they often push you into shipping as a parcel/package…..or push you into Priority rate….when it’s not necessary. It’s so annoying. Sometimes it’s best to ask to speak with the postmaster.

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