I use the foam or thin bubble wrap, too. Make sure you use the correct amount of postage. I save and reuse small padded envelopes. I can usually peel off the mailing label and put a new label over it. When I take the time to make and embellish a card, I don't mind paying extra postage. One thing I found out, is that handmade envelopes made from PATTERNED PAPER are rejected at the post office. You will not receive them back, either. Do you have any tools or devices to make envelopes?