I ship a lot of stuff to International CPF members using the
USPS .
About 50% of the time I use a Global Priority envelope, 20% using a padded envelope, and the last 30% using a box.
For small items it's cheaper (for the sendee) to use a padded envelope. As the sender, I don't charge CPF members for all the padded envelopes, package tape, bubble-wrap, and address labels that I buy and use. All that stuff adds up quickly. Either charge them for the supplies or stick to Global Express envelopes. They are free at the PO; grab a bunch of those and the customs forms.
For packages under 4 pounds and/or valued less than $300, use the small green Customs form 2976.
For packages over 4 pounds and/or valued more than $300, use the large white form 2976A.
You can't get insurance on Global Priority or Airmail Letter. You have to use Global Express or Airmail Parcel for insurance.
Tracking is only available using USPS and DHL. Global Express only tracks as far as US Customs.
For some reason you can't send Global Priority to Italy.
There's a rule of only one piece of tape allowed on the Global Priority envelopes. I always tape the four edges and the PO doesn't say anything as long as I don't put tape across the body of the envelope.
Unless I'm using a big box, I toss the blister packs because they take up too much room. If the item came in a cardboard box I remove it and collapse the box. That saves a lot of room.
I've had no problems, yet, with checking the gift box on the customs form. The people at the PO won't look at you, roll their eyes, and say "Yeah, Right". It saves the Sendee from paying Tax/Duty if the value declared is low enough, usually around $24, but it varies.
