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The biggest cost is mucking around with the artwork and layout yourself. Printing and shipping are minor costs by comparison. I guess its necessary if you want it to look good and don't want to pay an expert.
Get the free cards, pick one of their layouts, don't add any graphics.

Only costs $5 and you don't end up with a terrible nephew-art design. If you are having your own design the cost of the designer is going to dwarf the cost of the actual cards.

Have you seen the free "build your own" templates at VistaPrint? They're beyond horrible. I'd rather scrawl my email address on a napkin.