One of my first attempts at a print and play project last year, before Hex and Splut!, was micropul (BGG). I really enjoy the tile-laying mechanic of games like Carcassone, and micropul is a more lightweight and abstract implementation of a similar mechanic.
This is printed on cardstock, glued to foamcore, and cut with a craft knife. Foamcore was really too light and cut with rough edges, although it looks OK flipped over. Still, printed cardstock mounted on a vinyl floor tile and cut would be simpler and better in some ways.