Just to make sure I'm doing this right (first DVD export), I'm using both AE and PP at 720x480 w/ .9 aspect ratio. When I do the final export to MPEG-2 and slap it on a DVD to play on a regular TV, is there anything else I should consider about the resolution or aspect ratio?

Also, what kind of workflow do you guys use?

I'm capturing in PP, making my cuts and transitions, rendering and exporting to AE where I add effects and graphics then I do the final renders from AE as MPEG2-DVD.

What are you using to author to DVD?

The only other concern with your Mpeg-2 output is finding the optimal bitrate. Do some searching on that subject. High end authoring apps (like Encore) do a stellar job of auto-transcoding to the optimal bitrate. If that is where youa re going next, then its often safer to just export to AVI and let the Authoring app do the Mpeg transcode.

i never tried doing any mpeg encoding from ae, so i don't know what encoder it's using... in addition to what adam just posted, look for things like two-pass encoding capability and variable bit rate options.