Fitness Exercise Cards Video Introduction

Note: This is a past PVC OEM project displayed for manufacturing reference only. Not available for retail sale.

The client required a heavy-duty instructional deck capable of surviving high-moisture gym environments.

We engineered a solution using 0.3mm PVC paired with a specialized varnish. This combination balances extreme durability with the smooth handling required for frequent use.

0.3mm White PVC / Butter Varnish

Technical Specifications

Reference these specs when requesting a quote.

PVC waterproof fitness cards

Material Analysis: Why 0.3mm PVC?

Standard paper cores often delaminate under intense gym conditions. For this project, we utilized 0.3mm White PVC, a rigid synthetic substrate.

Key Performance Benefits:

• 100% Waterproof: The cards are impervious to sweat and moisture. They can be submerged or wiped down without damage.
• High Tensile Strength: The material resists tearing and creasing, even during aggressive handling.
• Superior Snap: Unlike thinner plastics, this gauge offers a “snap” and recovery similar to high-end casino stock.

💡 Insider Note: Printing on plastic can cause static issues, making cards stick together (known as “bricking”). To prevent this, we applied a Butter Varnish. This specific coating creates a microscopic texture that allows air to flow between cards, ensuring a smooth shuffle every time.

Custom Tuck Box

Packaging: Structural Tuck Box

The deck is housed in a bespoke tuck box engineered for both shelf stability and physical protection.

• 350gsm C1S Art Paper We selected this heavyweight stock to support the density of the PVC deck, which is significantly heavier than standard paper cards.
• Matte Lamination This non-reflective finish provides a sophisticated, velvet-like tactile feel. Crucially, it increases the box’s resistance to scuffing during shipping and retail display.
• Precision Color Matching The color coding on the box exterior was calibrated via GMG Proofing to match the card edges, ensuring strict brand consistency.

Print Precision & QC

Printing on non-porous plastic requires specialized UV inks and curing processes to ensure adhesion and sharpness.

• High-Definition UV Offset We achieved crisp legibility on small instructional text and complex diagrams, such as the detailed “Pistol Squat” breakdown.
• Die-Cutting Tolerance The design features distinct color markings on the card edges. Our die-cutting tolerance is maintained within ±0.5mm. This ensures the edge indicators align perfectly when the deck is stacked.

Ready to Engineer Your Own Deck?

Does this specification fit your product needs?

This page demonstrates our manufacturing quality. All specifications—including size, material thickness, and packaging—are fully customizable to your brand’s requirements.

• Reference This Sample: Mention “PVC Fitness Deck Case” when contacting us.
• Test the Quality: Request a sample pack to feel the PVC and Butter Varnish firsthand.