I was there with my kids, but I really don’t know anything about print numbers. We got ours in our hands because we just returned to our hotel room when they were indeed slipping them under the doors.
Perhaps a 500 of them printed sounds like a reasonable estimate.
Outside N-America the Nationals Champions got an invite with hotel and the winner of the only Stadium Challenge in 2005 in Austria.
No gym Challenge or Regionals international.
Japanese players had a different invite structure.
Worlds 2005 was in San Diego and players were spreaded around on the 4 or 5 buildings of the resort.