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I've seen it mentioned many times here over the years as well, so this seems to be commonly held belief that box size will increase the shipping cost. Where some folks are asking to have their items de-boxed for shipment. I kinda just took it on face value as fact that it did in fact impact the shipping cost, even though my own experience in shipping orders should have raised this question much earlier and challenged this idea. So instead I took your offer on the single Petshop as good exercise example =)
I set up an estimate on USPS using the weight of 100 ounces (~2,820g) along with its approximate measurements to fit in a shipping box of 23"x19"x4" dimensions. Shipping would be from NYC (10022) to LA (90277) and the estimated costs were:
Express = $69.70
Priority = $38.60
Regular = $25.03
I then re-entered the values of weight and destination, but changed the package to reflect a deboxed Petshop that was placed into a shipping box of dimensions 13"x10"x3" only. I still then got the same estimated costs to ship as before:
Express = $69.70
Priority = $38.60
Regular = $25.03
So why are folks thinking that shipping costs would be cheaper just simply because its without the original box?
But if shipping by the most common courier of USPS, the Regular 1st Class shipment parameters are <70lbs (max of 31,000 grams) and max package size of 108" total girth. So we are nowhere even close to hitting any limits whether by weight or package dimension size.
The weight of the Pet Shop box itself is 450g and you can calculate the exact savings if you deleted this weight from the previous 100 ounces. It would save a whopping $2.05 from the initial cost of $25.03 ($22.98 is adjust price without box). But then again, you might find folks out there that would prefer the $2 change than want the original box.
@wrangler6915 - exactly true. The few times that I've shipped larger sets, the girth was over 108". I have shipped a few sets in the Lego shipping boxes, and I was terrified that one stomp would damage everything. Proper reinforcement of the box requires a fair amount of space - pushing the cost ever skyward.
So compared to $11.95 for commercial base medium flat rate box it is a big difference. Even a 12x12x8 box (non flat rate) priority at the 7.5lb rate is $28.61 for those zip codes, which makes a large flat rate still a better deal.
USPS does pricing based on "dimensional weight" so even if it doesn't max out the 108" limit the price does start to go up drastically based on weight and distance.
I can send a like 4lb 8x8x7 box anywhere from NY/PA up through New England for like $7 since I'm in the Boston area, but that same package to CA is $17. So even if the flat rate boxes are overkill on size they are cheaper.
All of this is one reason why the USPS never seems to make money. Their pricing is way too complicated and it changes like every 6 months and never makes sense.
Thanks!
(And for record keeping purposes: @kiki180703)
@BrickDancer - I always appreciate the discussion. And any opprotunity to hijack a thread!