Good call on ordering them early. The times that we have been for the MNNSHP and the MVMCP, they have been sold out, and not very crowded at all. I would hate for you to miss out with all of the planning that you have already done.
Also, I think that you are going the right direction having them mailed, not printing them. They are hard tickets with characters on them and Halloween themed, but there are several pics and styles. They are not all the same. The NSSHP and the MVMCP tickets are very cool to have for scrap-booking and keepsakes. We still have all of ours... and even all of our Keys To The Kingdom cards from all of our trips. We are nerds like that.