Is there a way to make form letter variants in MSWord without VBA?

Create a document using OLE. These are the objects used by VBA.

But there's another way. Creating an XML document, which will be a document MS Office. In this case, the MS Word.

XML - that's fine. There are a number of XSLT processors, including the msxml. And most importantly the ability to convert one XML document into another XML.

Accordingly, we can come up with a convenient initial XML (template) that by converting the document will Wordml.

To generate MS Office not needed. Cross-platform.

Well now you can spread the fire and arrange the dance.

And some of the links below.

Word Content Control Toolkit

Transforming Open XML WordprocessingML to XHTML Using the Open XML SDK 2.0

Open XML SDK 2.0 for Microsoft Office

Open XML scenarios

Office 2003 Tool: WordprocessingML Transform Inference Tool

Transforming XML to WordML

Stylesheets for converting Microsoft's WordprocessingML documents to XSL FO (XSLFO)

Document Generation using WordML (Word 2003)

PDF! Office 2003 XML Oreaily

Word 2003: XML Software Development Kit (SDK)

Processing all Content Parts in an Open XML WordprocessingML Document

The Easy Way to Assemble Multiple Word Documents

Create a rich Word document based on your own custom XML (without the need for XSLT)

Visual How To

Word 2007 Content Tollkit