Here is what I have found through much trial and error. I have my covers printed at Office Depot/Office Max. They have professional quality printing services available there. Honestly, they look just as good as whatever Nintendo uses. Truly, the quality is fantastic if done right. Just bring a USB drive to their print station with all the covers on it. If you want a feel and quality that is identical to actual Nintendo DS cover inlays, I would suggest having them printed on 80lb or 100lb Glossy Elite paper. I typically go with 80lb, but 100lb is slightly thicker. It's just preference, though I find the 80lb to be closer to Nintendo's own cover inlays. Alternatively, you can always bring in an actual DS cover inlay as an example, to show which kind of paper you are wanting to print on. They tend to print kinda dark, so ask them to play with the print/image settings to account for this. Ask them to do a single test print first. They generally won't charge you for this. My only complaint is that they tend not to cut the prints very well, so you can always ask for the prints not to be cut. This also saves you a "cutting fee". I would recommend buying a precision cutter if you want perfect edges. Their rates are pretty reasonable for what you are getting. I think about $0.75 a print... Maybe cheaper...? Either way, the quality is well worth it in my opinion. Very rarely an employee might nag you about copyrighted images, etc. I usually just explain that I'm printing them for personal use and that I'm just printing one of each cover - not in bulk or anything suspicious. I've never had them refuse to print something. Once things are to your liking, have them print some up and you are good to go! Good luck!
