AUSTPost module

[RodG]

The badges themselves are under 1cm high, and up to 3 cm in diameter. I can fit five easily into a size 0 padded bag, and at least 20 into a size 2.

Unfortunately, what *you* can fit into a bag isn't going to be the same as what the AP module considers will fit. The algorithms to do that are far too complex for me, and are in fact considered something of a holy grail among some programmers.

The algorithm used by the AP module is a very simple "stack by height, keep track of maximum widths and lengths".

I've set the dimensions on my first test badge to .2 cm high and 1x1cm with a weight of .0001 kg, but I'm still getting only parcel options when I order one badge. Not sure what I'm doing wrong there.

Although probably not relevent, but is there a reason for you to be weighing your items in Kgs when gms seems to be much more suited?

I say 'probably not relevent' because it *shouldn't* be relevent, however, I can't recall what precision level I am performing the math functions with, which means that after multiplying and rounding this item may end up with an effective weight of zero, in which case the minimum weight allowed by parcel will be applied, thus nullifying the letter rate options (it does this to protect the merchant from under charging).
In other words, try changing your weights from kgs to gms, OR, add a little more mass to your badges, eg, 0.001kg.

Also check your TARE weight settings. These weights get added to the total product weight, which may be pushing your weights over the limits.

I'm very concerned that when customers are trying to order 20 badges it'll force them to parcel, even though I know it can send as a large letter. I'd appreciate any advice.

This can and probably always will be an issue, because there are far to many different scenarios that need to be considered when producing a program such as the AP module. There is always going to be someone that needs something 'special'. Usually a compromise and workaround is often the best solution. In your case, I would suggest considering setting up special departments for 'bulk buys' and using the weights/dimensions of the package containing the combined items for shipping purposes.

That, or very carefully select your badge dimensions so that the stacking algorithm produces the results that you require, while still being 'realistic'.

Cheers
Rod.

PS. Please keep in mind that as well as 'stacking' items, the AP module always re-orientates them prior to stacking. This means that regardless of how you/we view an item, the AP module treats the longest dimension as the length, the shortest dimension as the height, and the remaining dimension as the width.