Sometimes you can get lucky and find a local printer that has experience doing cards.
That is the first hurdle...because although they will be realitively inexpensive (as opposed to big printing companies with large minimum orders) they don't always know what they are doing.
I can't remember what the first run of the All hallows Majors cost me...I think it was something like $20 per deck...but the cost went down the more of them I bought...and I could only buy a few at a time. (that price was for 27 double sided cards per deck on decent card stock, and laminated)
The upside...I could just put jpegs of the images on a disc and they did all the formatting and everything for me...
The downside...they kept messing up the order, and even with all their fancy equipment couldn't seem to get the colors right, or the borders lined up properly...or even cut them straight all the time. Oh...and they also didn't have a working corner rounder, so I had to do all that by hand (as well as trimming the lamination)
They ended up fixing most of the problems eventually...but then they "accidently" printed too many decks, and ended up selling them to me at a discounted rate. Which is why there was a second edition.
They also screwed up the printing of the Minute deck...which isn't easy, since it's essentially one sided color copies on heavy cover stock.
Still...they were the cheapest thing I could find at the time, and they were local, so I could go in every day and yell at them if I needed to.
I think that NOW both the printers and myself... have a better understanding of how to make a card deck too.