Well I certainly agree that having a hard wearing card can be a bonus. For builders, mechanics, car sales and many other plastic is a very good option in this respect.
I think you're making a mistake though assuming printing is a simple matter. My business partner made the very same error many years ago. It wound up nearly bankrupting him! Having invested in machinery and even doing some manufacturer's training, he still couldn't compete with time-served craftsmen. Eventually he had to find the money to bring in an experienced printer. And for a few years he was sailing very close to the wind.
The big printers like Watson's tend to be able to invest in many different processes; and of course that particular firm is several generations old. But even that aren't the answer to 'everything'. As you say, a lot of jobs get 'farmed out'. For that reason I always suggest that clients use independent designers such as yourself to oversee the complete process. That way they can be sure the right person is doing the right job. Jack of all trades was master of none remember!
It's a bit like building a house; it's not a good idea to let an architect lay bricks nor is a brickie likely to be best placed to draw up plans! Though each seem blissfully unaware of just how hard the other's job really is!
But I don't think designers should shy away from bold design. An emboss or an overlay can be expensive yes; but if the rest of the design is in keeping such a device can make a bold statement about the person presenting it...
http://www.laseresque.com/servlet/the-29/wood-business-calling-card/Detail http://www.plasmadesign.co.uk/metalbusinesscards.htm I've certainly seen some very impressive business cards from HK. But of course etiquette over there sets rather more store by these things. Gold leaf's not that uncommon though; it's a traditional bookbinding material, and 20-0dd years ago a lot of foil work was done using genuine leaf.
