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It probably also depends if you are only shipping within your own country or internationally. I use padded envelopes to send within the UK and sometimes to Europe if the pony is sturdy and I can pack it well, but not often do I do that to more distant destinations. And yeah, the obvious about delicate ponies and boxes you probably already realised xD. I stockpile boxes from items received and recycle them to send items out. At least, I did until my dad started commandeering my box spares to send copies of his book to places that ordered them. Sigh. All my nice Japanese boxes are gone .I can't help in terms of USPS pricing.
Yeah, buy bubble mailers in bulk! Last time I bought these: 9" x 14.5" bubble mailers.I can fit two adult G1 ponies and one baby G1 pony in each, or three G1 adults depending on their pose.