I have used Printer Studio now, and found them to be fine. With regards the tarot cards, you have to select how many cards you want in the deck from the drop down menu. So, you could have 80 to make the standard sized deck. It then gives the price for one deck, of that many cards. ($16.50 for linen finish) With Printer Studio, if the order was over $30 postage was free. And they are quick in their turn around and their delivery.
With regards the boxes, you get a free tuck box if it is a standard playing card sized deck you have printed (54 cards) and that applies to the large cards also.
I have only had the bridge sized printed on plastic (which is my favourite finish by far) and large printed on linen (which is also excellent as a finish)
If anyone wants to know the pixel size I used for a) the image and b) the overall canvas size so as to add a border I can happily post that here). I used gimp to size the image then size the canvas/centre the image before uploading to their site.
There is a fair bit of maths involved, I do accept that, and my partner helped me out for my first attempts when using bridge size. I also have the dimensions I used for bridge and large saved for future use, as well as tarot size. Be aware though - I do add a border, due to the fact I don't want to have any image of the card cut off when it comes to the cutting process. They cannot guarentee the blade will come down dead centre but overall, they have only been off by a few pixels - certainly not anything for me to be upset about.
I also had a mouse mat printed and that too came out fine.
The thing people don't take into account when uploading images (besides getting it so the whole box is filled as per their instructions) is the aspect ratio of length x width. It varies dramatically between bridge and tarot cards. Tarot will be longer and thinner in comparison. So, if you start with a bit of a chunkier image, when you size it to fit, it will be stretched. Which may mean some images look a bit odd. Reverse happens if you go from tarot to bridge. It is shortened and fattened slightly. If you can trim parts off - fine. It shouldn't show. But if you can't, be aware of what size will best suit what you are uploading.
The attached shows both linen finish and plastic cards from my silhouttes Lenormand ... there is no difference between them, other than the plastic feel great and have the robustness about them for me to feel happy not wrapping them in cotton wool each time I use them. The 2nd photo is of the large cards in linen. It came with the tuck box.