Size of the box is also a very important factor. Using the free USPS boxes, it can be double or even triple the cost of a tight fitting box. Size does matters ;) We currently have 20 different sized boxes in our warehouse.
We are trying to offer an amazing service but still remain competitive to current pricing.
Saying that, there will be a ton of people who will do anything to save a dollar. I value my time very highly and assume a lot of other people do as well.