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fold it into an oragami shape that can easily be unfolded without tearing?
What about rolling them up in a mailing tube? But I guess that would be expensive postage too!
Just out of curiousity, what if they can't solve the puzzle? 
try this an Amish/Mennonite letter fold and either mail it as is or put it in an envelope.
roll it up inside a test tube, then mail that in a mailing tube.
FI and I are both scientists too! We've got a few different science things in our wedding - including using Erlenmeyer flasks as our flower vases on the tables!
I remember when I took chem a few years ago the prof handed out mini periodic tables that were the size of a business card...they really handy for exams and they were not too hard to read....perhaps you can try that
love the test tube idea!! maybe you could use the plastic shot tubes, the ones that people take shots out of so that you don't run the fear of them breaking....
Ooh, I love origami. How about a Japanese heart fold? It would be really cute if the opposite side of the paper was coloured or patterned.
Or you could just fold them up normally and tuck them into a library card pocket - you could make them out of pages from old science books. I think that would be adorable!
Just wanted to say I LOVE your STD....sooooo creative! I would be so excited to get that in the mail. How FUN!
I don't have any more folds to contribute but I did want to add that as a fellow scientist(with a scientist fiance!) I love your Save-the-date!
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FI and I are both scientists so we're doing a science-themed STD. Basically, it'll be a puzzle that guests have to solve by matching numbers and letters using a chemistry periodic table as a key. I'm really excited that it'll be representative of us and quirky and unique at the same time.
Here's the problem: the periodic table needs to be big enough for people to read so they can solve the puzzle, but that means that the print-out is 8.5" x 11" (no cute postcards for us!)...so how can I fold/present/send it in a cute way so that it's not just tri-fold in a standard envelope like a business letter? We don't want to mail them out flat in the huge envelopes since the postage will be too much, but I've been racking my brains and can't think of anything fun at all!
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