Renew by mail ($130) — Skip the $35 acceptance fee. Eligible if your last passport was issued within 15 years, you were 16+, and it's undamaged.
DIY passport photos ($0.35) — Take them at home with a white wall and print at CVS/Walgreens for $0.35 instead of paying $15-$20.
Apply in winter (Oct-Jan) — Fastest processing. Spring/summer adds 2-4 weeks due to travel season volume.
Passport card ($65) — Valid for land/sea travel to Canada, Mexico, Caribbean. Not valid for international air travel.