Is there another way besides a catch-all to create an email address for my wife to use that would show as her name on my domain when sending?

You can set up email accounts in 'Email Account' section in the control panel. You can add email accounts such as somename@yourdomain.com.

thanks for the info.
Reason i asked is the last provider i had charged extra for additional names.

Dynu allows up to 300 accounts without additional charge. There is a limit of 10 GB storage, which is quite sufficient.