I use
https://www.bitaddress.org to print me some bills. Then i cut them and fund with whatever small amounts i need. I write the value they carry by hand after funding with an android phone. The page script is clients side so the priv keys are in your possession at all times so you can even save the page as html and it will work. I'm not affiliated in any way just using the service.
I'd love to see this automated in the official frontend client - select amount, hit print.
I don't like the temptation of reusing bills. Reusing instead of tearing up and making a new one really defeats much of the point of Bitcoin doesn't it. Same for holograms really; I prefer those for promotion.