A couple of years ago a friend told me about Vistaprint and I've been using them ever since. You design the card on their website and then they mail them to you - professionally cut and finished.

Their basic card designs are free if you let them put their little ad on the back (you pay shipping only for 250 cards). From this point you can add upgrades like not having the ad, full color, glossy, double-sided etc.

I know I probably sound like I have shares in the company but I'm just a satisfied customer.

Here's their site:
http://www.vistaprint.com