Stephen, here's what I'd do.
First, I'd make the product and have it available as digital download. Of course this is simple and requires no work. There's no point in worrying about replicating, fullfillment houses, etc unless you know your moving a certain amount of units. All you do by doing this is create stress and risk, don't even worry about it or have it on your mind.
I would also create the physical product. And I'd do this by simply making 100 DVD's in house. You could even just make 25, whatever you feel comfortable with. This means I'd buy my own DVD cases, burn them on my own computer, etc. If/when those 100 or 25 you made in house sell, then go to replication if you feel the wheels spinnin' on this deal.
I can give you contact information to my DVD replicator where I get DVD's, shrinkwrapped, ready to go for .56 cents. I've been paying .95 per DVD forever and this company would have saved me thousands of dollars. So to be honest, it's so easy to go physical these days there's simply no excuse not to. They require 1,000 minimum orders but for under $600.00 you'll have $50,000 worth of inventory for next to nothing if you charged 50$ per DVD for example. PM if interested.
I would also ship them from my house at the beginning if I were you and just have the return address to a P.O. Box. It ain't that hard and doesn't take long. And if it does take to long that means you're making a lot of money and someone else can do it anyway so it's a no brainer.
I see so many people (not saying you'd do this) that plan all this stuff and get too involved with the BS that doesn't matter. I'd do it just like I said. It's simple and there's virtually no risk.
I love the DVD information business and plan on expanding into other niches within 5 years once I get our current business where I want them. It's just too easy.
And if you think about it, there's no reason to not be selling anything physical in today's age. You can have a website up and built, be taking payments, and selling your own DVD in ANY niche for under like $400.00. I get excited just talking about it!
