Main Takeaway: For domestic shipments of boxes in the United States, USPS Flat Rate Boxes offer simplicity and predictability for items up to 70 lbs, while UPS Simple Rate and FedEx One Rate deliver flat-fee alternatives with their own box-size tiers. Non-flat-rate ground services (UPS Ground, FedEx Ground) are generally more cost-effective for larger, heavier, or longer-distance shipments, but rates vary by weight, dimensions, distance, and service level.
1. USPS Flat Rate Boxes
USPS Priority Mail Flat Rate boxes let you ship any weight up to 70 lbs anywhere in the U.S. for a fixed fee. No weighing or zone-based pricing is required, though additional surcharges may apply for nonmachinable parcels or oversized dimensions.
1.1 Retail vs. Commercial Rates
¹Commercial Pricing requires online Click-N-Ship or postage meters.
| Box Type | Outside Dimensions (L × W × H) | Retail Price | Commercial Pricing¹ |
|---|---|---|---|
| Small Flat Rate Box | 8 11⁄16″ × 5 7⁄16″ × 1 3⁄4″ | $10.40 | $8.51 |
| Medium Flat Rate Box (Top Loading) | 11 1⁄4″ × 8 3⁄4″ × 6″ | $18.40 | $14.38 |
| Medium Flat Rate Box (Side Loading) | 14″ × 12″ × 3 1⁄2″ | $18.40 | $14.38 |
| Large Flat Rate Box | 12 1⁄4″ × 12 1⁄4″ × 6″ | $24.75 | $19.51 |
| APO/FPO Large Flat Rate Box | 12 1⁄4″ × 12 1⁄4″ × 6″ | $24.75 | $17.70 |
1.2 Key Points
- Weight Limit: 70 lbs maximum for all Flat Rate boxes.
- Delivery Speed: 1–3 business days (Priority Mail service) with USPS Tracking included.
- Surcharges: Parcels over 1 ft³, over 30 inches in length, or non-standard shapes incur extra fees.
- Comparison: Flat Rate is best for dense, heavy items that fit the box. For lightweight or large low-density items, weight-and-zone pricing may be cheaper.
2. UPS Simple Rate
UPS Simple Rate is a flat-fee shipping option (ground service) that allows use of customer’s own packaging up to 1,728 in³ and ships up to 50 lbs without delivery area surcharges. Pricing depends solely on box size, destination (zone), and delivery speed.
2.1 Box Size Tiers & Starting Prices
Exact rates vary by zone and delivery speed. See UPS account or partner portal for zone-specific pricing.
| Size Tier | Cubic Inches Range | Starts at (Ground) |
|---|---|---|
| Extra Small | 1–100 in³ | $9.45 |
| Small | 101–200 in³ | – |
| Medium | 201–400 in³ | – |
| Large | 401–1,050 in³ | – |
| Extra Large | 1,051–1,728 in³ | $24.30 |
2.2 Key Points
- No Proprietary Boxes Required: Use own packaging up to 1,728 in³.
- Weight Limit: Up to 50 lbs.
- Insurance: Automatically includes $100 declared value.
- Service Levels: Ground (1–5 business days) and slower five-day option available at lower rates.
- Account Requirement: No existing UPS account needed; rates available through participating partners.
3. FedEx One Rate®
FedEx One Rate offers guaranteed flat pricing for FedEx Express domestic services (overnight, 2-day, 3-day) using FedEx-provided packaging types. Rates depend on packaging type and delivery commitment within contiguous U.S. areas.
3.1 Packaging Types & 2-Day Rates (0–150 miles)
Rates are identical for FedEx Express Saver® (3-day) and FedEx 2Day; higher for expedited A.M. and Next-Day services.
| Packaging Type | Dimensions (approx.) | FedEx 2Day® |
|---|---|---|
| FedEx® Envelope | 9 1⁄2″ × 12 1⁄2″ | $10.95 |
| FedEx® Pak | 10 1⁄4″ × 12 3⁄4″ | $13.75 |
| FedEx® Small Box | 10 7⁄8″ × 1 1⁄2″ × 12 3⁄8″ | $16.75 |
| FedEx® Medium Box | 11 1⁄2″ × 2 3⁄8″ × 13 1⁄4″ | $21.00 |
| FedEx® Large Box | 12 3⁄8″ × 3″ × 17 1⁄2″ | $28.50 |
| FedEx® Extra Large Box | 11 7⁄8″ × 10 3⁄4″ × 11″ | $37.75 |
| FedEx® Tube | 6″ × 6″ × 38″ | $37.75 |
3.2 Key Points
- Delivery Commitments: FedEx Express Saver® (3 days), 2Day®, 2Day A.M., Standard Overnight®, Priority Overnight®, First Overnight®.
- Weight Limits: Envelopes ≤ 10 lbs; Boxes/Paks/Tubes ≤ 50 lbs.
- Declared Value: Up to $100 included; higher values at extra charge.
- Fuel/Accessorials: Additional fees for Saturday, signature options, pickup, and remote areas.
- Packaging Supply: Free at FedEx Office or via account order.
4. Non-Flat-Rate Ground Services
For shipments that exceed flat-rate box dimensions, weights, or when weight-and-zone pricing is more economical (e.g., lightweight or oversized packages), UPS Ground and FedEx Ground offer zone-based rates.
4.1 UPS Ground (Estimated)
- Delivery: 1–5 business days; zones based on miles.
- Rate Factors: Dimensional weight divisor = 166; actual vs. dimensional weight used.
- Sample Short-Distance Rates (packages under 10 lbs):
- 1–5 lbs: $8–$14
- 6–10 lbs: $15–$20
(Estimates; use UPS calculator for precise quotes).
4.2 FedEx Ground & Home Delivery (Zones 2–8)
(Zones reflect distance tiers; heavier weights incur higher per-pound rates).
| Weight | Zone 2 | Zone 5 | Zone 8 |
|---|---|---|---|
| 1 lb | $11.32 | $13.27 | $14.17 |
| 2 lbs | $12.08 | $14.84 | $16.40 |
| 5 lbs | $13.29 | $17.56 | $20.48 |
5. Choosing the Best Option
- Dense, Heavy Items (≤ 70 lbs) & Free Boxing: USPS Flat Rate often wins for medium-weight, high-density goods that snugly fit USPS boxes.
- Customized Boxes & ≤ 50 lbs: UPS Simple Rate allows use of own packaging with transparent flat fees and no surcharges.
- Time-Sensitive, Air Service Needs: FedEx One Rate ties packaging to delivery speeds (overnight to 3 days) with predictable pricing.
- Large, Light or Oversized Items: Ground services (UPS/FedEx) with dimensional weight pricing are generally cheaper than flat rates.
- Distance Sensitivity: Regional Rate (discontinued by USPS) and zone-based ground services adjust costs by destination, so short-distance ground can be very economical.
Conclusion: No single solution covers every scenario. Assess each shipment’s weight, dimensions, speed requirements, and packaging flexibility to determine whether USPS Flat Rate, UPS Simple Rate, FedEx One Rate, or zone-based ground services yield the most cost-effective shipping.
¹ Commercial Pricing refers to online postage options via Click-N-Ship, business accounts, or postage meters. Citations web:1 web:2 web:12 web:24 web:25
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