Over the past two years we’ve mailed close to 1000 free PCBs all over the world. We find that a sturdy envelope and a stamp is the cheapest, and somewhat successful, way to mail PCBs.
A new wiki page shows the tricks we use to mail PCBs. The how-to is reproduced here for you blog viewing pleasure.
PCB – The thing you want to mail.
Masking tape – Masking tape isn’t super sticky. It’s easy to remove later, and doesn’t leave a bunch of gunk on the PCB.
Sturdy envelope – It’s a trade off between envelope quality and weight (=stamps). We use envelopes made of thick paper, the thickest we can find. Don’t cheap out, crappy envelopes will always tear in automated mail sorting equipment.
Address label – The goal is to create a reinforced pocket for the PCB. The address label from our label printer is a key part of our technique. These labels are super strong and tear-proof, they do a great job protecting the envelope from the corners of the PCB.
Stamps – Most small PCBs will mail with a single stamp. PCBs bigger than 3x3inches may need two stamps.
Step 1. Tape the back of the PCB
Put a piece of masking tape on the back of the PCB.
Step 2. Tape the PCB to the inner front of the envelope
Slip the PCB in the envelope and tape it against the front bottom of the envelope. The PCB should sit behind the label – we want to make a reinforced pouch between the masking tape and the label.
Step 3. Make a pocket with the mailing label
We put a the sturdy label from our label printer on the front of the envelope against the PCB. The outline of the PCB is visible under the right side of the label.
The PCB is sandwiched between tape on one side, and paper and the label on the other. This seems to give the best chance that the envelope will make it.
Step 4. Put on a stamp
Or two, if it’s a heavy PCB (bigger than 3x3inches).