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So, I might be shipping out hundreds of models soonish and am sort of perplexed as to how I can do this and keep them safe and not spend hundreds. Anyone around have any experience bulk shipping like this? I am going to be forced to break up the shipments into smaller ones?

Apologies if this isn't where this goes.

Well, for one, I'd say look at UPS ground. They seem to be on the cheaper side for large shipments. Second, be prepared to spend up to $100 depending on how much you're shipping. I'd just look at it as the more you pay up front, less likely something breaks and you have to refund the guy.

Bubble wrap each piece.

Bubble wrap the inside of the box.

Either bubble wrap the bubble wrapped pieces, or put them in a large box with Styrofoam peanut chips.

Get insurance, depending on value.

Alternatively, and depending on location, hand deliver. I twice got cheap flights for less than postage would have been, and had a short break into the bargain.

stroller wrote:
Bubble wrap each piece.

Bubble wrap the inside of the box.

Either bubble wrap the bubble wrapped pieces, or put them in a large box with Styrofoam peanut chips.

Get insurance, depending on value.

Alternatively, and depending on location, hand deliver. I twice got cheap flights for less than postage would have been, and had a short break into the bargain.

You get a free trip out of it too lol.

most of the time i see units in zip locks then surrounded by bubble wrap
seems to work fine

stoller's advice is solid, especially in terms of insuring and double wrapping.

Another option would be to use memory foam mattress toppers like this one.

A twin-sized topper will run you under $20 which is cheaper than some rolls of bubble wrap.

You can place models into the depressions in the foam and then place another foam piece on top sandwiching the models in place. You can put multiple layers in a box, and the weight of the top layers keep the models on the bottom layers from shifting.

I was initially really skeptical about this method of shipping having always used bubble wrap in the past, but my regular commission painter uses this method almost exclusively and it has resulted in minimal breakage or paint chips during transit. I've since shipped multiple painted armies in this manner and had great success.

Mattress topper also reminds me. I got hold of some laptop transport boxes. Essentially a cardboard box with two intercut layers of eggcrate foam. That works pretty well too.