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Shipping Rules and Label Help

Shipping Rules and Label Help

We have a store with a bit of a unique shipping set up. We ship both domestic (USA) and international. All orders domestic come with free USPS priority mail(set up in shopping cart rules) or an option of FedEX based on location. For international orders, we charge a flat rate to the customer if their order is below a certain value (set up as flat rate in the back end). If the international order is over that set value, then they too will receive free shipping (via USPS international). They also have the option for FedEX based on location.


Our main goal is to be able to create and print shipping labels for all orders being shipped via USPS, both domestic and international. With the current settings it does not allow us to create any USPS shipping labels, just the packing list. I've read around and it seems our goal is not achievable in the standard Magento 1.9 backend. 


With that being said, is there an extension or custom code that would allow us to a.) create shipping labels for each order no matter what shipping method is used, b.) have shipping rules as listed in the first section (free domestic, flat charge or free for international depending on order value)


Currently we have to use USPS online to create each label manually, which ends up taking 15-20 hours a week due to number of orders coming in.


Thanks for any help!