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I only have experience in mailing Netflix DVDs. They are in a sleeve and a rectangular envelope. The envelope is obviously much larger than the DVD and sleeve, but it seems to work out well!
You might be able to use media mail (cheaper than first class).
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My FI is creating a STD video to be mailed out as DVDs. We were thinking of just mailing them in DVD sleeves with the addresses in the cellophane window. I know it will cost extra postage to mail a square envelope, which I dont really care too much about. But I'm just wondering if anyone has mailed out DVDs before and if you have any tips for doing so??
Thanks!