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I had no trouble mailing a microSD card in just an envelope (though I also suspended it between 3 pieces of cardstock and a letter--the postal system doesn't mind if you mail a thin object in an envelope as long as it can move around, and is small enough to survive going through the rollers). A friend also mailed me a regular SD card that was just shoved between a christmas card, and it came in fine.
Worst case, you could ask them to hand cancel it to avoid it going through the rollers. It costs a little more.
As for overseas mailing, I'm not sure.
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