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I ship fabric most times in the flat raters. They are sometimes as thick as 6"....filled to the capacity that I can hardly close it. Just "secure" it with my ONE piece of tape across the flap.
I've shipped this way for 6 years. I was told years ago about the "1 piece of tape rule", so if any postal clerks ever say anything, I tell them that and tell them to ship it.
I do beleive now, there is a 4 pound limit on the flat rate envelope, though.
what is the "1 piece of tape rule".
Everytime before I ship, I go to the USPS site, and check the postage.
According to what I was told years ago, and what I have done since, you can stuff the flat rate envelopes, but only use 1 piece of tape across the flap to hold it closed.