For our escort cards I decided to keep it simple. I've seen a lot of really great ideas, but we needed to cut costs somewhere so this was one area that we didn't want to put a lot of money into. I purchased actual escort cards from Walmart and they were on clearance for $10 a pack. I only needed one pack. Chester will be printing them (free) and I created the design for them myself.
I did a test print today at work using just regular paper. I'm actually really happy with it and I love that you can download the template for the paper online so it makes it pretty fool proof with lining everything up properly.
Here's a picture of how it looks (again, it will be on nicer cardstock style paper)
I'm pretty content, but I am going to try to think of a solution for weighing them down somehow. I was even thinking of going to home depot and buying those flat washers or something and gluing them to the inside of the card. I just don't want them to blow away.