Everyone I talk to loves the first "minicard" someone gives them, and hates every subsequent card. You want your cards to be the standard bcard form factor.

I use Moo Mini Cards, and people seem to love it. It has a good finish and you get to customize it in different colors. I had 4 different colors and people loved it. But not being a standard business card form does tend to be a pain for people who have standard spot for it in their wallets or desk.

I second Moo.

However, I always have my professional designer create the cards and http://sbprintthis.com/ handles the printing.

Unless you're a crack graphic designer yourself, there's not substitute for having them professionally done. Think back to cards you've received. Which ones stand out? I'll suspect that it's either the ones with a schtick - Matt Mullenweg's plain white "Type Matt into Google and click I'm Feeling Lucky" cards - or the beautifully designed ones printed on heavyweight stock.

It makes a difference.