Disclaimer: This is a past manufacturing project showcased for reference only. The artwork belongs to the respective creator and is not for retail sale.

Project Background & Challenge

A recent publishing partner approached us for custom flash card printing. Their primary goal was to utilize a non-standard, tarot-sized format (70x120mm) designed specifically for maximum toddler engagement.

The core manufacturing challenge was engineering the press sheet imposition. We needed to accommodate this oversized format without inflating the unit cost for the publisher.

Custom Toddler Flash Cards / Matte Lamination (Both sides)

Technical Specifications

• Product Type: Toddler Flash Cards
• Card Dimensions: 70 x 120mm (Tarot Size)
  • Detail: Die-cut with R3.5 rounded corners for strict child safety compliance.
• Card Count: 60 cards per deck
• Card Stock: 350gsm C2S (Coated Two Sides) Art Paper
• Printing & Ink: CMYK Full Color Offset
  • Detail: Printed utilizing eco-friendly, soy-based inks (CPSIA/ASTM compliant).
• Surface Finish: Matte Lamination (Both sides)
• Packaging: Custom Tuck Box
  • Detail: Constructed from 400gsm SBS (Solid Bleached Sulfate) board with matching matte lamination.

Custom Tuck Box

Metal Binding Ring

Craftsmanship & Material Highlights

• 350gsm C2S Art Paper + Matte Lamination
  • Benefit: Delivers the exceptional structural integrity and snap required for frequent toddler handling.
  • Benefit: The matte lamination eliminates harsh indoor glare, reducing eye strain while enhancing ink saturation and contrast.
• Eco-Friendly Soy-Based Ink
  • Benefit: Ensures 100% non-toxic, safe contact.
  • Benefit: This is a critical compliance factor for publishers requiring strict safety certifications for children’s products.
• 400gsm SBS Heavy-Duty Tuck Box
  • Benefit: Delivers superior crush resistance compared to standard 300gsm folding cartons.
  • Benefit: It prevents structural failure and tearing during repeated opening and closing by kids and parents.

Factory Note: Maximizing Plate Yield & Cost Efficiency

Insider Tip from Our Press Room:

When running a 70x120mm card (which requires a 76x126mm footprint with standard bleed), a standard offset press sheet yields a maximum of 40 to 45 cards per form.

Because this specific deck requires 60 cards, it necessitates a two-form press run. This leaves approximately 20 unutilized slots on the second printing plate.

Our Value-Add Recommendation:

Rather than running blank paper on the press, we advised the client to maximize their plate yield by adding supplementary cards—such as a brand intro card or a “How to Use” guide.

Since prepress and plate-making costs are already absorbed by the initial 60 cards, adding these extra components incurs only a fractional increase in raw material cost. This strategy drastically elevates the deck’s perceived value without impacting the production budget.

Use This Spec as a Reference for Your Project

Like the manufacturing specs of this project? [Request a free sample pack] to evaluate the 350gsm matte finish and card snap firsthand.

Alternatively, inquire about this spec to see how we can engineer the optimal press layout for your custom card count. All parameters shown here are fully customizable to meet your brand requirements.