h**p://auspost.com.au/internationalpost/products/eci/index.html (wouldn't let me post the URL due to being a new member) seems to be the only thing that Australia Post offer internationally that is fast or more importantly trackable. USA is Zone C according to Australia Post so it's $41.10 for a 500g prepaid envelope. The envelope is also cardboard so your photos won't get damaged in transit (my NL looks like a dog ate it because it's been bent that many times prior to delivery.)
I am sending my stuff off tomorrow so if you can recommend something else before then let me know.
What is everyone doing for their photos?
I have Photoshop so I was thinking of putting the two 2" x 2" photos in the middile of a a 6" x 4" with a 1cm white boarder so they can be trimmed, inserting my case number in the whitespace in the upper right corner, then using a photo kiosk to print the finished image.
Last week when I was in the US the Kodak kiosk at CVS had a US passport photo template that did 2" x 2" prints and checked the demisions of your head are correct. I haven't used a Kiosk in Australia for a while, I assume if you select passport they'll print the Australian size?
Regarding the photos, the ones you send to KCC with your completed DS-230 etc don't even get used. When you go to your interview you have to take another recent photo (less than 6months old) and that is what is used for your visa.
We just got regular passport photos done for the 1st NL set of documents then when we went to the interview there was a kodak shop downstairs from the consulate building in Sydney that did US visa photos which meet the size requirements.