I found that I could get full colour printing on medium card for $2 a page so I went for full armies.
Early Imperial Romans
It worked out fairly well. With the Scots, I positioned the individual elements by hand with space to cut between each. This meant two cuts were needed to remove the white space between elements and thus sore hands. For the Romans, I used a grid to position each element on the page with a touch extra to allow for trimming. To make things even simpler, I used a guillotine to cut - bad move. despite my best efforts, the card slid around on the guillotine,the cut line was hard to see and as a result, a couple of imperial foot commands came up a little "short".
In future, I will use the grid and black cut lines but trim by hand. Once you get the rhythm, its straightforward and accurate. Still - DBMM card armies are a lot harder on the cutting hand than DBA.