eins78 welcome!
We have similar goals.
I am launching openpaperwallet.com, an open source site (and github repository) for coordinating a design, open and free graphics, instructions, software etc. All dedicated to the open paper wallet.
I will be "forking" that into a commercial bulk operation, my first print run is about 10,000 notes, of three designs, to bring the cost down and afford high quality offset, emboss, microperf die and good paper.
Once the software is tweaked, I will be able to add a new paper design with a github pull request from any designer.
The website itself will also be open source. I'm looking for CSS3/HTML5 designers to help me make a barebones multi-platform site that can be easily hosted on a variety of cloud and hosting providers.
If you want to help, please join the effort!