This is a past project displayed for manufacturing reference only. Not available for retail sale.

Project Context Manufactured for an educational publisher, this project required high durability for frequent classroom handling.

We balanced vibrant print quality with structural integrity using 300gsm C2S stock and scuff-resistant matte lamination. This ensures the cards resist corner fraying and maintain a flat profile after extensive use.

Custom printed travel knowledge cards with matte lamination sample for educational publishers.

Technical Specifications

Reference these specs for your quote.

• Project Type: Educational Flash cards / Custom Deck
• Card Size: 89 × 127 mm (Custom Vertical Format)
• Stock (Material): 300gsm C2S Art Board (Coated Two Sides)
• Printing: 4/4 Full Color CMYK (Offset)
• Surface Finish: Matte Lamination (Both sides)
• Packaging: Rigid Lid & Bottom Box with Midriff (Neck)
• Component Count: 50 Cards + 1 Box

Production Insights

Why this configuration works for mid-to-high volume runs.

1. Cost-Effective Imposition The 89 × 127 mm dimension is a strategic choice. It fits efficiently on our standard offset sheet sizes.

• Benefit: Maximizes the number of decks per run and significantly reduces paper waste compared to non-standard large formats.

2. Material Selection: 300gsm C2S Standard flyer paper lacks the necessary “snap” (memory) for educational tools. We utilized 300gsm C2S Art Board for excellent stiffness and opacity.

Director’s Note: For strictly educational use, C2S is the most cost-efficient choice. If you require casino-grade shuffling performance, we recommend upgrading to 310gsm German Black Core.

3. Lamination for Longevity We applied a thermal matte lamination rather than a standard varnish.

• Durability: Adds a plasticized layer that prevents ink from cracking at the edges.
• Readability: Diffuses light, making text easy to read under harsh classroom lighting.

Lid-bottom Box Midriff  Vertical

Rigid lid and bottom box packaging with midriff for card deck manufacturing.

Packaging Engineering

Rigid Box Construction for Retail & Logistics.

Structure: Lid-and-Bottom with Midriff (Neck) We engineered a custom vertical box to house the 50-card deck securely.

The inner neck (midriff) creates a friction seal, preventing the box from opening accidentally during shipping or retail handling. It also allows for a contrasting color reveal, adding a premium aesthetic.

Structural Integrity Constructed with 1200gsm Greyboard (approx. 2mm thickness) wrapped in 157gsm art paper.

This heavy-duty construction provides superior crush resistance, ensuring your product arrives in pristine condition.

Start Your Custom Project

Planning a similar project?

You can use this project as a reference for your inquiry. We can adjust the card count, size, or upgrade the material to Black Core based on your budget.