Ok, this isn't exactly free but it comes pretty close.
This idea came to me from willy wagtail who offers a tutorial on getting the most out of free, or almost free, business cards at Vista Print.
I've ordered from them many times in the past and, honestly, have never been disappointed.
I went through MyPoints to place my order and earned 300 points for doing so. I'm saving MyPoints, Huggies, Coca Cola, and Swagbucks points to buy Christmas gifts (although the Coke Rewards site is currently down ... wonder what the story is there).
Above is the card I ordered. Easy peasy, lemon squeezy.