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Re:Amazon's minimum order size for free shipping is now $35 by nknighthb on Tuesday October 22, 2013 @03:33PM (#6594306)
I'm sure they lose money or are right on the edge with some Prime customers.

That said:

* Large-volume shippers have always gotten much lower prices than you'll get walking into a UPS store. Amazon is an uber-volume shipper.

* Their warehouse network minimizes the actual distance products must travel on average.

* I naïvely assume they've worked with carriers to optimize how they interface with them (both digitally and physically; e.g. boxes stacked/arranged in certain ways for pickup).

* Amazon often does not have the lowest prices for things, especially small/cheap items. If you buy a $5 widget you could have gotten for $3 at the local hardware store, some of that is probably making up for cheap shipping.

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