What Is Business Card Printing

How the process works, from file preparation to finished card

What Business Card Printing Is

Business card printing is the manufacturing process that turns a digital design file into a physical card, typically measuring 85 by 55 millimetres in Europe or 3.5 by 2 inches in North America. The process involves translating on-screen colours into ink on paper, cutting sheets to size, and applying any requested finishes such as lamination, foil, or embossing.

Although the end product is small, the workflow behind it shares the same core principles used to produce posters, packaging, and books. Ink is deposited onto a substrate, the substrate is dried or cured, sheets are trimmed, and finished cards are inspected for defects before shipping.

Several distinct printing methods exist, each with its own strengths. The most common are offset lithography, digital printing, letterpress, thermography, and foil stamping. The choice of method depends on budget, quantity, desired finish, and turnaround time. Understanding how each works helps you make better decisions when ordering cards and communicating with print suppliers.

File Preparation and Print-Ready Artwork

Before any press runs, the design file must be prepared to meet the printer's technical specifications. Mistakes at this stage are the single most common cause of disappointing results, so it is worth understanding what "print-ready" actually means.

CMYK Colour Mode

Screens display colour using red, green, and blue light (RGB). Printers reproduce colour by mixing cyan, magenta, yellow, and black inks (CMYK). Because the two systems work differently, colours that look vivid on screen can appear dull or shifted when printed. Converting your design file to CMYK before sending it to print ensures the colours you see on the proof are as close as possible to the final output.

Some printing companies also support Pantone spot colours for precise brand matching. If your brand guidelines specify a Pantone reference, check whether your chosen printer can work with spot colours. This is more common with offset printing than with digital.

Resolution

Print files need a minimum resolution of 300 dots per inch (DPI) at the final card size. Images pulled from websites are typically 72 DPI and will appear blurry or pixelated when printed. Vector graphics, such as those created in Adobe Illustrator or exported as SVG, scale to any size without losing quality and are ideal for logos and line art.

Bleed, Safe Zone, and Trim

Cards are printed on large sheets and then cut to size. Because cutting machinery has a small tolerance, three zones must be accounted for in every design file.

Zone	Purpose	Typical margin
Bleed	Background extends beyond trim to prevent white edges	+3mm outside trim
Trim line	The intended finished edge of the card	The card dimensions
Safe zone	No critical content beyond this line	3mm inside trim

If your background colour or image does not extend into the bleed area, you risk thin white strips appearing along one or more edges after cutting. Equally, if text or logos sit outside the safe zone they may be trimmed off entirely.

File Formats

Most commercial printers accept PDF files prepared to the PDF/X standard. This format embeds fonts, preserves CMYK colour information, and supports bleed marks. Some printers also accept Adobe Illustrator (AI), Photoshop (PSD), or high-resolution TIFF files. JPEG and PNG files are generally unsuitable because they use RGB colour, apply lossy compression, or lack bleed information.

Tip:

Always ask your printer for their file preparation checklist before you begin designing. Requirements vary between companies and between printing methods.

The Main Printing Methods

Each printing method deposits ink onto paper in a different way, and each produces a slightly different look and feel. Here is how the five most common methods work.

Offset Lithography

Offset printing uses metal plates, one for each CMYK colour, that are etched with the image. Ink is applied to the plate, transferred to a rubber blanket roller, and then pressed onto the paper. The indirect transfer is where the name "offset" comes from.

Because producing the plates requires setup time and cost, offset printing becomes economical only at higher quantities, usually 500 cards or more. Once the press is running, however, each additional card costs very little, making it the most cost-effective method for large runs. Colour consistency across a long run is excellent, and the process supports a wide range of paper stocks and special inks including metallics and Pantone spot colours.

Digital Printing

Digital presses, whether toner-based (similar to a laser printer) or inkjet, print directly from the design file without plates. This eliminates setup costs and makes digital printing the most affordable option for short runs of fewer than 500 cards.

Modern digital presses achieve quality that is very close to offset, and improvements in colour management mean that the gap continues to narrow. Digital printing also allows variable data printing, where each card in a batch can carry different information, which is useful for organisations that need personalised cards for a large team.

Letterpress

Letterpress is the oldest printing method still in commercial use. A raised plate is inked and pressed firmly into thick, soft paper, leaving a debossed impression that can be felt with a fingertip. The tactile quality is the main appeal of letterpress business cards.

Letterpress works best with simple designs using one or two ink colours. Photographic images and gradients do not reproduce well. The process requires heavy cardstock, typically 600 gsm or above, which contributes to the premium feel but also increases cost. Letterpress cards are significantly more expensive than digital or offset, and turnaround times are longer because the work is often done by specialist studios.

Thermography

Thermography creates a raised, slightly textured surface by dusting wet ink with a resin powder and then heating it until the powder fuses and swells. The result mimics the look and feel of engraving at a fraction of the cost.

It is often used for text-heavy designs such as legal or financial business cards where a formal, traditional appearance is desired. Thermography is not suitable for very fine detail or large solid areas of colour, and the raised surface can crack if the card is bent.

Foil Stamping

Foil stamping applies a thin metallic or pigmented foil to the card using a heated die. The die presses the foil onto the paper, bonding it to specific areas of the design. Gold, silver, copper, and holographic foils are the most popular choices.

Foil stamping is usually combined with another printing method, for example digital printing for the main design with a foil-stamped logo. It adds significant visual impact but also increases cost and production time. The die must be custom-made for each design, so there is an upfront tooling charge.

Paper Stock and Weight

The paper, or substrate, affects how the card feels in the hand, how well it holds up in a wallet, and how ink is absorbed. Paper weight is measured in grams per square metre (gsm). Heavier paper feels more substantial and is generally perceived as higher quality.

GSM range	Description	Typical use
300 to 350 gsm	Standard weight	Budget and everyday cards
400 gsm	Mid-weight	Most standard commercial cards
450 to 500 gsm	Heavyweight	Premium feel, good rigidity
600 gsm and above	Extra thick	Letterpress, luxury, layered cards

Coated vs Uncoated Stock

Coated paper has a thin clay or polymer layer that gives it a smooth surface. It comes in gloss, silk, and matte variants. Gloss coatings make colours appear more vivid and are good for photographic images. Matte coatings reduce glare and feel more understated. Silk sits between the two, offering a slight sheen without heavy reflection.

Uncoated paper has no surface treatment. It has a natural, tactile feel and absorbs ink more readily, which gives printed colours a softer, warmer appearance. Uncoated stock is easier to write on, which is useful if recipients will jot notes on the card. However, fine detail and photographic images reproduce less sharply on uncoated paper.

Cotton and Specialist Stocks

Cotton paper is made from cotton fibre rather than wood pulp. It has a distinctive soft texture and is the traditional choice for letterpress printing. Cotton stock is more expensive than standard wood-pulp paper but conveys a handcrafted, premium quality.

Other specialist substrates include recycled paper, kraft card (brown, unbleached), synthetic waterproof stocks, and even materials like wood veneer, metal, or transparent plastic. These options are niche and significantly more expensive, but they can make a strong impression in the right context.

Finishing Options

Finishing refers to any process applied after the card has been printed. Finishes protect the print, enhance the visual appearance, and add tactile interest. The most common finishing options are described below.

Lamination

Lamination bonds a thin plastic film to one or both sides of the card. Gloss lamination intensifies colours and adds shine. Matte lamination creates a smooth, velvety feel and mutes reflections. Soft-touch lamination (sometimes called velvet lamination) is a variant of matte that gives the card a suede-like texture, which many people find pleasant to hold.

Lamination also makes cards more durable, protecting them from scuffs, moisture, and fading. It is one of the most cost-effective finishing options and is widely available from both digital and offset printers.

Spot UV

Spot UV applies a glossy, raised ultraviolet coating to selected areas of the card while leaving the rest of the surface matte. It is commonly used to highlight logos, text, or graphic elements. The contrast between the matte background and the glossy spot-UV areas creates a striking visual and tactile effect.

Spot UV is typically applied over matte lamination for maximum contrast. It requires an additional print pass and a separate file indicating which areas should receive the coating.

Aqueous Coating

Aqueous coating is a water-based protective layer applied to the entire surface of the card during the printing process. It dries quickly and adds a subtle sheen that is less intense than gloss lamination. Aqueous coating protects against fingerprints and smudging and is more environmentally friendly than plastic-based lamination.

Edge Painting

Edge painting, also called edge colouring, applies ink or foil to the exposed edges of the card stack. It is most effective on thick cardstock (450 gsm and above) where the edge is wide enough to be visible. Edge painting adds a pop of colour that is immediately noticeable when the card is handed over or placed in a cardholder.

The process is done by hand or semi-manually, which makes it more expensive than machine-applied finishes. It works well as an accent alongside letterpress or foil-stamped designs.

Cutting and Sizing

Business cards are printed multiple-up on large sheets, meaning many cards are arranged on a single sheet and printed in one pass. After printing, the sheet must be cut into individual cards. The standard sizes vary by region.

Region	Standard size	Notes
UK and Europe	85 mm x 55 mm	ISO 7810 ID-1 format
United States and Canada	88.9 mm x 50.8 mm (3.5" x 2")	De facto standard
Japan	91 mm x 55 mm	Meishi format, slightly wider
Square	55 mm x 55 mm or 63 mm x 63 mm	Non-standard, premium positioning

Guillotine Cutting

The most common cutting method uses an industrial guillotine that slices through the entire stack of printed sheets in a single stroke. The sheet is positioned against a back gauge, the blade descends, and the cut is made. The process is repeated for each edge of each card.

Guillotine cutting is fast and accurate, typically within a tolerance of plus or minus 0.5 millimetres. It produces clean, straight edges and is the standard method for rectangular cards. Rounded-corner cards go through an additional step where a corner-rounding die punches each corner after the straight cuts are made.

Die Cutting

Die cutting uses a custom-shaped steel blade, formed into a die, to stamp out cards in non-rectangular shapes. The die is pressed through the printed sheet, cutting all edges of the card in a single action.

Die cutting is used for cards with custom shapes, such as circles, ovals, leaf shapes, or cards with cut-out windows. The die itself is a one-time expense, usually between 50 and 150 pounds or dollars, after which it can be reused for future orders. Die-cut cards stand out from standard rectangles but may not fit neatly into standard cardholders or wallets.

Quality Control and Common Print Defects

Reputable printers carry out quality control checks at multiple stages of production. Understanding common defects helps you evaluate the cards you receive and communicate effectively if something is wrong.

Colour Shift

Colour shift occurs when the printed colours do not match the proof or the on-screen design. Small shifts are normal because of differences between screen and print colour spaces, but significant shifts may indicate a press calibration issue. Requesting a printed proof before the full run is the best way to catch colour problems early.

Banding

Banding appears as visible horizontal or vertical stripes in areas of gradient or solid colour. It is more common in digital printing and is usually caused by low resolution in the source file, insufficient ink coverage, or a worn print head. Ensuring your file is 300 DPI and using smooth gradients reduces the risk.

Misregistration

In multi-colour printing, each ink colour is applied in a separate pass. If the passes do not align perfectly, the result is misregistration: a visible gap or overlap between colours, often seen as a thin white or coloured halo around objects. Misregistration is more common in offset printing, where mechanical tolerances affect plate alignment.

Cutting Deviation

If the cutting machinery is slightly misaligned, cards may end up with unequal margins or a design that appears off-centre. This is why the bleed and safe zone exist. Cards with full-bleed backgrounds are more forgiving of small cutting deviations than designs with precise border lines, where even a 0.5 mm shift is noticeable.

Hickeys

Hickeys are small, circular spots or rings that appear on printed cards, caused by dust, dried ink, or paper fibres on the press roller or plate. They are more common in offset printing. A good printer will catch hickeys during quality checks and clean the press before continuing the run.

What to do if you spot defects:

Inspect your cards as soon as they arrive. If you find consistent defects across the batch, contact the printer immediately with photographs. Most reputable printers will reprint the order at no charge if the fault lies with their production process.

Frequently Asked Questions

What is the difference between digital and offset printing for business cards?

Digital printing works directly from a file without plates, making it faster and cheaper for short runs of fewer than 500 cards. Offset printing uses etched metal plates and becomes more economical at higher quantities because the per-unit cost drops once setup is complete. In terms of quality, modern digital presses produce results very close to offset, though offset still holds an edge for exact Pantone colour matching and very large solid-colour areas. Choose digital for speed, flexibility, and small quantities. Choose offset for large orders, precise colour matching, and the widest range of paper options.

Why do my cards look different from what I see on screen?

Screens use RGB light to display colour, while printers use CMYK ink. The two colour spaces do not overlap completely, so some on-screen colours, particularly bright blues, vivid greens, and neon tones, cannot be reproduced exactly in print. Additionally, the paper stock affects how colours appear: uncoated paper absorbs more ink and produces softer colours, while coated paper keeps colours vivid. To minimise surprises, convert your design to CMYK before sending it to print, calibrate your monitor if possible, and request a printed proof before approving the full run.

What GSM should I choose for my business cards?

For most professional uses, 400 gsm is the standard and offers a good balance of rigidity and cost. If you want a premium feel, move up to 450 or 500 gsm. Budget cards are often printed on 300 to 350 gsm stock, which is adequate but can feel flimsy. If you are ordering letterpress cards, you will typically need 600 gsm or above to achieve the characteristic deep impression. Keep in mind that heavier stock increases shipping weight and cost, particularly for large orders.

What is bleed and why does it matter?

Bleed is the area of your design that extends beyond the intended trim edge of the card. It exists to account for the small inaccuracies inherent in mechanical cutting. Without bleed, any slight shift in the cut would leave a thin white strip along one or more edges. Most printers require 3 mm of bleed on all sides. In practice, this means your background colour or image should extend 3 mm past the card dimensions, and your file should be set up at the card size plus 6 mm in both width and height.

What is variable data printing?

Variable data printing (VDP) is a feature of digital presses that allows each card in a print run to carry different information. For example, a company can print 200 cards with a consistent brand design but a different name, title, phone number, and email address on each card. This eliminates the need to run separate print jobs for each employee. VDP is only available with digital printing because offset plates cannot change between impressions. It is particularly useful for organisations that need to order cards for a large team in a single batch.

What does soft-touch laminate feel like and is it worth the extra cost?

Soft-touch lamination applies a matte film with a velvety, suede-like texture. When people pick up a soft-touch card for the first time, the tactile sensation is immediately noticeable and often draws a positive reaction. It also resists fingerprints better than gloss lamination. The extra cost is typically modest, adding a small percentage to the per-card price. For professionals in client-facing roles where the card is part of a first impression, soft-touch lamination is generally considered worth the investment. It pairs especially well with spot UV, where the contrast between the matte soft-touch background and glossy raised elements creates a striking effect.

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