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What is the best way to ship minis these days. Key points being affordable and least likely to have your package kicked around and stuff broken? Is it US Postal Service, UPS, Federal Express or another carrier?

USPS flat rate. You just need to pack them well.

UPS is horrible about on-time delivery and handling your packages with care. At UPS, Fragile means "Throw this like a football."

In my experience, your milage may vary, and so on.

as long as you pack them well they should ship well ie make sure models have plenty of foam and not in contact with other models, a piece of foam and a foam cutter can do wonders to make a cheap foam tray for seperation

Let me put it this way. I have friends who have worked for UPS and FedEx. If they want something to get where it's going undamaged they send it USPS.