There is nothing like a good price bump to kick your ROI in the teeth!

But the USPS is doing a couple of things right now to help reduce the cost of DM
1. I suggest personalization over saturation mailing but if you think saturation might work for you "every door direct mail" is a new program from the USPS.
http://www.usps.com/promotions/everydoordirectmail.htm
Every Door Direct Mail enables you to extend your customer reach via saturation mail without the need for mailing lists, permits, and the associated fees. With Every Door Direct Mail, you create a saturation mailing without applying individual names and addresses to each mailpiece.
2. The USPS is offering a 3% discount on postage for mail with QR codes this summer
http://sumgould.wordpress.com/2011/0...s-summer-2011/
As for print well I don't have and good ideas just this moment but if I come up with one ill let you know.