Steps
Buy a plain brown mailing box. Make sure that the box is the correct size - you don't want the box too small or too large. (When mailing from the U.S. go to www.usps.com and go to SUPPLIES and click on FLAT RATE. You will find flat rate boxes for APO/FPO addresses. These are for troops overseas and the USPS will mail you these boxes for free. The shipping costs for the flat rate is usually cheaper than shipping by weight, depending on what you are sending.)
Make sure anything you are planning to send (toothpaste, sanitizer, etc) is in travel-size accessories. It will be a lot easier for marines to carry around with them.
Tape the box up really well after you are done. If you are taking the box to a local or non-military post office, you may either be rejected (as they don't send to POs), have to pay a fee, or need to fill out a customs form. You'll also need to fill out a customs form if taken to a military post office.
Find a Service-member's address. Remember to write it correctly. Use this format: (Name): SSGT. G. I. Joe; (Street/Box): 1st Grenade Repair Co. 123 Dud Testing Btn (City, State, Zip) APO, AA 32145
Preparation
Figure out what your Service-member wants - even if they don't use it or prefers not to - they tend to give it to another Service-member who does; so don't worry what you put inside.(Just a note that there are Female Service-members overseas too.)
Look for the cheapest needs: grab a handful of $1 toothbrushes, travel medicine such as Tylenol packs, generic brand things, etc. Generic baby wipes are important, as they use them for cleaning themselves and their weapons.
Think of things that a marine would enjoy while in cots or their sleeping area. Car, sport, and gaming magazines are excellent. Travel games, pens, paper, notebooks, envelopes, and extra calling cards are great for communication. They don't need stamps because they can mail letters back to the states for free. AA Batteries are a top priority item, as they use it for CD players, other portable items, flashlights, and anything else that requires batteries.
Making The Box
Put everything in Ziplock bags. This is to avoid sand and other things getting into the stuff. It also helps the military, as they in turn, use the bags for other uses.
Secure cookies and other candies very well before putting it into the box. If you are sending food like these, make sure you plan to send it as soon as possible.
Wrap laptops and other very important valuables in bubble wrap a few times and tape it up very well.
Send miscellaneous items (such as cotton swabs) in their original packaging.
Restrictions
Avoid anything that can melt. Iraq can get up to 120 °F (49 °C) or higher.
Ensure that care packages stay rated PG-13 or lower. Leave all "personal" situations between you & your partner when they come home. This means omit all adult only items out of it.
Leave all sharp and dangerous items out - all boxes are inspected. Try not to put lotions, soaps, & toiletries that have aroma and food in the same box. You don't want your service member to get cookies that taste like foot lotion.
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