I've been using micro SDHC cards to send files through the mail in standard business envelopes tapped to three sheets of paper.
2 out of 4 Samsung 8GB cards couldn't be read or written to when they arrived at their destinations.
A Kingston 16GB card made it back and fourth once. It was taped to a small piece of cardboard on it's return trip back to me. I sent it out again without any cardboar. It arrived safely but when it was slipped into an SDHC adapter, it split in half.
Of course they're fragile. They're tiny, flat bits of plastic.
Is there a particular reason you need to send physical media? You'd pretty definitely have better luck exploiting an online file sharing service like Dropbox or setting up an FTP server on your source computer.
I'm sending very large files to a friend in the UK who has a limited download plan per month.
So, dropbox or ftp isn't an option.
Sending one 4GB DVD in a padded envelope costs $5.
I thought sending an 8GB or 16GB or 32GB micro SDHC card every now and then would be cheap and convenient.
One or two micro SDHC cards in a business envelope is over $1.
2 micro SDHC cards in a very small padded envelope is $3.
I thought a business envelope would bend where it had to bend with enough chance that it wouldn't bend where the micro SDHC card is taped to three tri-folded pieces of paper.
also, any xray machines might be wiping the card contents.
Xray's do not effect flash memory.
Like other people have said I highly doubt the problem is the card and instead the packaging. Remember the mail has lots of rollers, sorters, etc.
A padded envelope will help and they should be quite cheap yet. They small plastic cases that I think in your case would be well worth the few dollars they cost. Most cards I have bought come with them anyways.
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