The beauty of currency to go (if you don't do it too frequently) is that you can get travelers checks charged to a credit card, so your cash purchases are actually getting miles. I order TC and a small amount of currency for the country I am going to. I usually use the ATM's because the exchange rate seems to be the best, European ATM's do not charge fees, and neither does my Citibank ATM card. I also use my starwoods AMEX card - even though I might be "paying" a little more, I get those miles and a record of my expenses. What I don't use in those Travelers checks I can deposit to pay off the credit card charges. I do not know of any other bank that lets you buy US travelers checks by charging to a credit card. Chase does not charge for delivery - it is a slight inconvenience for me for what they are giving you.
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DtG