Is It Cheaper to Send a 5 Pound Package via USPS or UPS for Next Day Delivery?

When you need to send a 5-pound package overnight, the difference between USPS and UPS can save you serious cash-or cost you more than you expected. It’s not just about the sticker price. It’s about delivery speed, reliability, hidden fees, and whether your package even qualifies for the rate you’re hoping for. If you’ve ever stared at two shipping quotes and wondered why one’s $15 cheaper than the other, you’re not alone.

USPS Priority Mail Express for 5 Pounds

USPS Priority Mail Express is their fastest option for domestic next-day delivery. For a 5-pound package, the starting price is $28.75 if you print the label online using USPS Click-N-Ship. That’s for delivery by 6 p.m. the next business day to most U.S. addresses. If you drop it off at a Post Office, it’s $30.25. No fuel surcharges. No residential delivery fees. No dimensional weight tricks. What you see is what you pay.

USPS uses its own network and partners with local carriers for final delivery. That means even if you’re in a rural area, your package still gets delivered. No extra charge. No surprise. And if it doesn’t arrive on time, USPS guarantees a full refund. That’s rare in shipping.

But here’s the catch: USPS Priority Mail Express doesn’t deliver on Sundays in most places. If you ship Friday night, you’re looking at Monday delivery. That’s not next day if you need it by Saturday. Also, it only covers the 50 states and D.C. No APO/FPO or international. If your recipient is in Alaska or Hawaii, the price jumps to $42.50.

UPS Next Day Air for 5 Pounds

UPS Next Day Air is their standard overnight service. For a 5-pound package, the base rate starts at $48.50 for commercial addresses and $52.75 for residential ones. That’s nearly double what USPS charges. And you’re not done yet.

UPS adds a residential delivery surcharge of $4.25 on top of the base rate if you’re sending to a home. Then there’s a fuel surcharge-currently 14.5%-which bumps the total up to $60.40 for a residential delivery. That’s $31.65 more than USPS. And you didn’t even get a guarantee that it’ll arrive before noon. Next Day Air is just “next day,” not “by 10 a.m.” If you need guaranteed early delivery, you have to pay for Next Day Air Saver or Next Day Air Early, which costs $65 or more.

UPS also uses dimensional weight pricing. If your box is big but light, they’ll charge you based on volume, not actual weight. A 5-pound package in a 12x12x12-inch box could be charged as 10 pounds. That’s an extra $15-$20 right there. USPS doesn’t do that for Priority Mail Express. They charge by weight only.

Why the Big Price Gap?

USPS is a government agency. It’s required by law to serve every address in the country at uniform rates. That means they can’t pick and choose where to deliver. UPS is a private company. Their goal is profit. They charge more to cover the cost of delivering to remote areas, avoid losses on low-margin packages, and fund their air fleet.

USPS delivers 500 million packages a week. UPS delivers about 25 million. That scale lets USPS negotiate better rates with its own rail and trucking partners. UPS has to pay for its own planes, drivers, and hubs. Those costs get passed on.

Also, USPS doesn’t have to pay corporate taxes. UPS does. That’s another reason why their prices are higher. It’s not about being “better.” It’s about structure.

When UPS Might Be Worth It

There are times when paying extra for UPS makes sense.

• You need delivery by 10 a.m. or noon. USPS Priority Mail Express doesn’t guarantee that unless you pay extra for Priority Mail Express with guaranteed delivery time.
• You’re shipping to a business, not a home. The residential surcharge disappears.
• You need tracking beyond “in transit.” UPS gives you real-time location updates, signature confirmation, and delivery photos.
• You’re sending high-value items. UPS offers $100 of default insurance. USPS only gives $50.
• You need to return the package. UPS returns are easier and cheaper.

If you’re shipping a laptop, jewelry, or medical supplies, the extra cost for UPS’s tracking and insurance might be worth it. But if you’re sending a box of books, clothes, or gifts? USPS wins every time.

Real-World Example: Shipping from Atlanta to Chicago

Let’s say you’re sending a 5-pound box of winter clothes from Atlanta to Chicago on a Tuesday. You want it there by Wednesday.

USPS Priority Mail Express: $28.75 (online label). Delivers by 6 p.m. Wednesday. Guaranteed. Refund if late.

UPS Next Day Air: $52.75 (residential) + $4.25 residential fee + $7.75 fuel surcharge = $64.75. Delivers sometime Wednesday. No guarantee on time. No refund if late.

That’s a $36 difference. That’s a meal for two at a decent restaurant. Or a new pair of shoes. Or a week’s worth of coffee.

What About Other Options?

You might think FedEx is cheaper. It’s not. FedEx First Overnight for 5 pounds starts at $58.40 for residential. Even their Economy service is slower and costs more than USPS.

Amazon Shipping? Not available to the public. DHL? Too expensive for domestic. Regional carriers like OnTrac or LSO? Only cover certain areas. If you’re outside their network, you’re stuck with USPS or UPS.

For 90% of people sending a 5-pound package domestically, USPS is the smart pick. It’s cheaper, reliable, and has fewer hidden fees.

Pro Tips to Save Even More

• Use a flat-rate box. If your 5-pound package fits in a USPS Priority Mail Express Flat Rate box (12x12x5.5 inches), you pay the same $28.75 no matter how heavy it is up to 20 pounds.
• Print labels online. Always. Dropping off at the Post Office adds $1.50.
• Ship early. If you drop off after 3 p.m., your package might not leave until the next day.
• Use a third-party service like Shippo or Pirate Ship. They give you discounted USPS rates-sometimes as low as $25 for Priority Mail Express.
• Don’t overbox. Use the smallest box that fits. UPS will punish you for oversized packaging.

Final Verdict

If you’re sending a 5-pound package and need it delivered next day in the U.S., USPS Priority Mail Express is almost always cheaper-and often just as fast. UPS is more expensive, adds hidden fees, and doesn’t guarantee delivery time unless you pay even more.

USPS wins on price, simplicity, and reliability for standard next-day delivery. UPS wins only if you need early delivery, high-value tracking, or signature confirmation. For most people, that’s overkill.

Next time you ship, check USPS first. You’ll save money. You’ll get your package there. And you won’t need to explain why your shipping bill is $65 instead of $30.