I, too mail mine in a #10(regular business size) letter envelope. Only costs $.44 each for me, too.
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am able to mail mine at regular postage of 44 cents. I use a regular long letter envelope and address it before inserting the block.. I fold the block almost in half, then fold again and then fold it to fit the envelope. I wrap the fabric block in saran wrap and press out the air. This way of packaging has been weighed several times at the post office to confirm the postage. If you use a manilla envelope it will cost about $1 to mail.