PS: If you decide not to buy a laser printer, there are some ways you can make your inkjet-printed wallets more water-resistant. I'll be posting a report on this soon as I'm in the process of testing a bunch of different products/solutions.

I'm re-reading this and now I'm undecided. I first thought it was a bounty. Is it?

First of all and I say this again... GREAT JOB!!!
I love the design and your website is great too!
Now to the constructive criticism:

I made my first paper wallet using your web site. There are no concerns there, it worked flawlessly, I used Safari and I used an ink-jet printer and the design is a work of art but I printed the wallet in photo/presentation paper which it's not a problem since I figured the paper is sturdy, makes the design look better and I believe it's more durable. That being said, the paper is not designed to be folded!!! to my surprise, the paper slightly broke when I folded (see photo here https://dl.dropboxusercontent.com/u/72382452/Photo%20Apr%2023%2C%2012%2038%2031%20PM.jpg)
So my concern is the private key in the inside of the fold. Could you find a gracious way to split the private key so the folding area does not tamper with the characters? I'm concerned about the folding messing with the characters and making them unreadable.
I'm sure this issue is not only associated to photo paper but any kind of paper since the fibers are broken when you fold a piece of paper.
I know the QR code is fine, but I'd feel better having redundancy (QR & actual private key)
Anyways, my 2cts for your design.

Great work again!

Done! I don't think the margins are ideal in the template (important content unnecessarily close to the paper edge) -- and I think it's a mistake to omit the public key from the backup stub -- but I've submitted a revised design that strictly conforms to the template.

https://tricider.com/en/display/104330?wicket:pageMapName=wicket-4

Hmm, I hope this is just a blurring/resolution issue from taking a screenshot and then shrinking the size and applying JPG. I'm using the same code and QR generator as bitaddress.org -- the only fundamental difference is the web interface, CSS/HTML and the background art.

Here's a non-downscaled sample. Would you see if the sample below reads correctly 10/10 for you? The QR codes when printed are quite sharp. Significantly sharper than this JPG.

http://i.imgur.com/03MhJNI.jpg

I worked on about 5 or 6 variations last night before I hit on this one which isn't significantly more difficult to cut out with scissors. In my own tests, this new shape overcomes this exploit while still using the original design that calls for two strips of 2" x .625" tamper-evident tape. (When you fold this new design up, the tape now sticks to all three "panels" in the folded area so the innermost panel can't be snuck out.)

Thanks again yellowcoin for the excellent experiment.

http://i.imgur.com/Cx4Tg8V.jpg

PS: Yes, those are live keys, but there's nothing stored in them this time. Yet.

Looks like it all went in a bunch about 12 hours later. Or maybe it was blockchain.info that was having problems? I could not access their wallet for a day afterwards.

1,021 BTC is a lot different than 1.021 BTC