My latest printing project is a business card-sized character sheet card. They measure just 85x55mm, yet still have room for the essential character details. I originally designed these as an extra item for an Oubliette PDF, but always intended to get some printed up. They have been professionally printed on sturdy matt card. You can buy them (£1.90 for a pack of 50) from my webstore: http://squarehex.myshopify.com/collections/role-playing-games/products/b-x-mini-character-sheets
I've also put them on ebay here: http://www.ebay.co.uk/itm/350955690503?ssPageName=STRK:MESELX:IT&_trksid=p3984.m1555.l2649
Squarehex.co.uk also has my other character sheet cards and pads