Custom Playing Cards for
Board Games & Tabletop Games
Engineered for durability, shuffle performance, and long-term play
Custom playing cards(game cards) are not simply printed paper products—they are precision-manufactured game components. We provide industrial-grade manufacturing solutions where card stock composition, coating chemistry, and cutting accuracy are engineered as a unified production system to ensure long-term durability and consistent shuffle feel.
Whether producing standard decks for board games or high-opacity collector editions, our process balances structural elasticity with surface texture. Utilizing FSC-certified cardstock and production-proven finishing processes, we deliver a crisp “snap” and edge-wear resistance suited for high-frequency gameplay and professional collectors.
We Provide All options for Custom Playing Cards
Custom Card Size Options & Standard Formats
Selecting the correct card size is a foundational decision that impacts gameplay ergonomics and tooling efficiency. We support both industry-standard formats and fully custom dimensions, engineered to integrate seamlessly with downstream production processes.
Standard Card Size
We manufacture all commonly used card formats for board games, card games, and tabletop products, including but not limited to:
Poker Size: 63 × 88 mm / 2.5 × 3.5 inch: The most widely adopted format for modern board games and card-driven mechanics.
Bridge Size: 57 × 88 mm / 2.25 × 3.5 inch: Preferred for games requiring easier hand management and reduced fan width.
Tarot Size: 70 × 120 mm / 2.75 × 4.75 inch: Commonly used for tarot decks, narrative-driven games, and titles requiring large-format illustrations or text-heavy layouts.
Mini / Euro Size: 44 × 68 mm / 1.75 × 2.65 inch: Ideal for compact games, travel editions, and titles with large card counts.
Square & Specialty Sizes:Common in deduction games, icon-driven systems, and abstract mechanics.
These formats utilize proven die libraries, enabling faster setup and cost-efficient tooling.
Custom Card Sizes
For games with unique layout requirements or bespoke visual design, we offer fully custom card dimensions.
Flexible Aspect Ratios: Custom widths and heights can be engineered to support specific artwork compositions or icon hierarchies.
Gameplay-Driven Sizing: Card size can be optimized for hand comfort, table footprint, or multi-card interaction mechanics.
Custom sizes are evaluated at the pre-production stage to ensure compatibility with printing, coating, and cutting workflows.
Tooling & Die Compatibility: Card dimensions directly affect die design and tooling reuse.
Standard Size Advantage: Using established formats allows reuse of existing cutting dies, reducing tooling cost and lead time.
Custom Die Engineering: New dimensions require dedicated steel dies, which are engineered for repeatability across long production runs.
Our engineering team reviews each size specification to balance design freedom with manufacturing efficiency.
Card Thickness, Weight & Flex Profile
Card thickness is a critical ergonomic factor that impacts shuffle feel, snap recovery, and player fatigue. We help you select the optimal grammage based on your deck size and gameplay mechanics.
Common Card Specifications
250–280gsm (Approx. 0.26–0.28mm): Ideal for party games or games with 200+ cards where deck height must be managed.
300–310gsm (Approx. 0.30–0.32mm): The industry standard for modern board games; balances durability with ease of shuffling.
330–350gsm (Approx. 0.34–0.38mm): Premium collector grade; offers maximum “snap” and a heavy, high-end hand feel.
Engineered Flex Performance & Shuffle Durability
Each card stock specification is validated against the following performance criteria:
- Snap Recovery: The card must return to a perfectly flat state after a 90-degree flex, ensuring no permanent warping
- Edge Resilience: Specifically engineered to resist “mushrooming” or splitting during aggressive riffle and overhand shuffles.
- Stack Stability: Balanced friction coefficients to ensure large decks remain stable on the table without sliding.
Thickness tolerances are strictly monitored via calibrated digital micrometers to prevent any “mixed-feel” variations between production batches.
Playing Card Materials & Cardstock Engineering
Card performance is defined by internal paper construction rather than surface appearance alone. Different core structures directly affect opacity, durability, shuffle behavior, and unit cost. At Funway, we manufacture playing cards using a full range of paper and plastic substrates to match gameplay mechanics, handling frequency, and budget constraints.
Below are the six primary material options we offer for custom playing cards and board game cards.
240-350gsm black core paper
(Top-tier anti-cheating · Maximum durability · Highest cost)
Black core paper is constructed by laminating a fully opaque black adhesive layer between two outer paper sheets. This internal carbon-black core is precisely centered to block light transmission from both face and edge angles.
Engineering Performance:
- Near-zero light transmission, even under strong backlighting
- Excellent resistance to edge marking and card bending
- Balanced flexibility and snap for repeated shuffling and flourishing
Recommended Use:
- Competitive and hidden-information games
- Professional-grade board games and casino-style decks
- Premium Kickstarter and collector editions
This is the most advanced and expensive paper-based option, selected when fairness, opacity, and long-term durability are non-negotiable
240-350gsm blue core paper
(Strong anti-cheating · High durability · Cost-effective premium)
Blue core paper features a blue opaque adhesive layer laminated at the center of the card. While slightly less opaque than black core, it still delivers excellent light-blocking and structural stability.
Engineering Performance:
- Very good opacity with minimal show-through
- Strong durability under frequent handling
- Lower material cost compared to black core
Recommended Use:
- Retail board games
- Strategy and family games with face-down mechanics
- Projects balancing performance and cost
Blue core paper is widely used as a high-quality standard for commercial playing cards and tabletop games.
240-350gsm white core paper
(Balanced performance · Best value-for-money)
White core paper uses a classic tri-layer structure with an opaque white adhesive core laminated between two paper faces. It delivers reliable durability and excellent print vibrancy.
Engineering Performance:
- Moderate opacity, with possible show-through under strong light
- Stronger durability than gray core alternatives
- Superior color reproduction and artwork clarity
Recommended Use:
- General board game cards
- Card-driven games without strict anti-cheating requirements
- Cost-sensitive projects requiring consistent quality
This material offers the best overall balance between performance and cost and is commonly used for standard retail card components.
240-350gsm gray core paper
(Entry-level opacity · Lowest cost)
Gray core paper incorporates a gray opaque center layer laminated between two paper faces. It provides basic opacity at the lowest material cost.
Engineering Performance:
- Light transmission between white core and blue core
- Lower durability and edge resistance
- Suitable for limited handling cycles
Recommended Use:
- Promotional decks and giveaway cards
- Prototype or short-term use projects
- Budget-driven productions
Gray core paper is selected when cost efficiency outweighs long-term durability requirements.
C2S Coated Paper
(Exceptional print quality · Smooth surface · Lower durability)
C2S (Coated Two Sides) paper is produced by applying a smooth coating to both sides of high-quality paper stock, creating a bright and uniform printing surface.
Engineering Performance:
- Outstanding color saturation and image sharpness
- Smooth, flat surface with no internal core layer
- More prone to creasing, moisture absorption, and edge wear
Recommended Use:
- Artistic decks and promotional cards
- Collector editions focused on visual impact
- Projects prioritizing print quality over shuffle longevity
C2S paper delivers premium visual results but is not ideal for heavy gameplay or frequent shuffling.
PVC plastic Cards
(100% waterproof · Maximum durability · Premium feel)
PVC cards are manufactured through a fully synthetic molding process with no paper layers. The homogeneous plastic structure makes them completely waterproof and highly resistant to tearing, staining, and deformation.
Engineering Performance:
- Fully waterproof and moisture-resistant
- Extremely long service life
- Can be produced in solid or transparent designs
Recommended Use:
- Outdoor and humid environments
- Casinos, hospitality, and event use
- Luxury custom decks and specialty applications
PVC cards represent the most durable option available and are selected when environmental resistance and longevity are critical.
Custom Playing Cards Printing Methods & Specialty Effects
Printing quality directly impacts color accuracy, edge clarity, and long-term surface durability. We engineer each printing method based on production volume, artwork complexity, and finishing compatibility to ensure consistent results from proofing to mass production.
At Funway, we support four primary printing technologies for custom playing cards, each optimized for specific design, production volume, and cost objectives.
Full-Color Printing (Digital & Offset)
(Baseline production solution for reliable color accuracy and scalability)
Full color printing: the most economical and reliable choice
For full color cards, to achieve a deep, rich, and true-to-life color spectrum, we utilize two precision printing methods: digital printing for limited editions and small runs, and offset printing for high-volume mass production. Both ensure exceptional color fidelity and vibrancy.
Engineering Application
Full-color printing serves as the structural baseline for most custom playing card projects, optimized for consistency, color fidelity, and cost control.
Production Method
Digital Printing is used for limited editions, prototypes, and short runs, allowing rapid turnaround and flexible variable data.
Offset Printing is deployed for mass production, delivering superior color stability, ink density control, and lower unit cost at scale.
Quality Control Variables
CMYK color profiling calibrated to card stock absorbency
Dot gain compensation to preserve fine line art and indices
Tight registration tolerances to prevent color shift at card edges
Best Use Cases
Standard board games, retail decks, and large-volume production where reliability and repeatability are critical.
Full-Foil Printing (Gold/Silver Foil Substrate Printing)
(Metallic substrate printing for luxury and collector-grade decks)
Gold/Silver foil stamping printing: high-quality and high-end
Gold/Silver foil stamping printing adds an extra elegant and expensive-looking touch to your deck of cards. It is the definitive way to turn any cards into a luxury deck and to give your custom cards a unique edge compared to others.
Engineering Application
Unlike traditional spot foil stamping, full-foil printing uses a fully laminated metallic film as the base substrate, with all artwork printed directly onto the gold or silver surface.
Production Method
- Card faces and backs are fully laminated with metallic foil film
- Specialized inks and adhesion primers ensure ink bonding on non-porous foil surfaces
- White ink underlayers are selectively applied to control opacity and color contrast
Quality Control Variables
- Ink adhesion strength under repeated flexing
- Scratch resistance and edge wear performance
- Controlled reflectivity to avoid glare during gameplay
Best Use Cases
Premium collector decks, luxury gift sets, and visually striking limited editions where metallic presence defines the product identity.
Full-Card Selective Spot UV Coating
(Graphic-level gloss control without compromising shuffle performance)
Spot UV printing: Showcases a sharply elevated pattern with a pronounced 3D look
Spot UV printing applies a high-gloss, clear coating to specific areas of your cards, creating a striking contrast between the vibrant, matte paper and the raised, reflective gloss. This technique adds a sophisticated texture and visual depth.
Engineering Application
This process applies selective UV gloss across precisely defined graphic elements throughout the entire card, rather than isolated decorative highlights.
Production Method
- UV mask files define coated areas at the artwork level
- High-precision registration ensures alignment between print and UV layers
- Controlled coating thickness maintains consistent friction across the card surface
Quality Control Variables
- Gloss-to-matte contrast uniformity
- Surface friction balance to prevent sticking during shuffling
- Edge buildup prevention to avoid premature wear
Best Use Cases
Premium decks requiring tactile differentiation and layered visual hierarchy while maintaining professional handling characteristics.
3D Lenticular Printing
(Optical motion and depth through engineered lens alignment)
3D lenticular printing: provide things out of the ordinary
3D lenticular printing brings your custom cards to life with captivating motion and depth effects. By overlaying a specialized lens on a precisely printed interlaced image, this advanced technology creates the illusion of animation, morphing, or a stunning three-dimensional view.
Engineering Application
3D lenticular printing introduces motion or depth effects using optical lens sheets bonded to interlaced printed imagery.
Production Method
- Artwork is digitally interlaced based on lens pitch specifications
- Printed sheets are precision-aligned and laminated with lenticular lenses
- Final die-cutting maintains lens alignment across all cards
Quality Control Variables
- Viewing angle accuracy and motion clarity
- Lamination stability under flexing
- Increased thickness tolerance for deck stacking
Best Use Cases
Promotional decks, special editions, and novelty products where visual impact outweighs shuffle frequency.
Surface Finishes & Texture Treatments
Surface finishing directly affects card handling, glare control, abrasion resistance, and long-term durability. We apply finish systems at controlled thickness and curing parameters to ensure consistent tactile performance across every deck. Finish selection is engineered in coordination with cardstock, printing method, and intended gameplay intensity.
Soft Touch Lamination
Soft touch lamination is a premium specialty film engineered to deliver a distinct tactile experience. It cures to an ultra-matte, non-reflective surface with a velvety, suede-like feel that immediately communicates high perceived value.
This finish enhances color depth without gloss glare, making artwork appear richer and more controlled. While it provides effective protection against moisture and edge fraying, its soft surface requires careful handling, as it can be more sensitive to oils or deep scuffs compared to hard-coat laminations.
Engineering characteristics:
Ultra-matte, non-reflective surface
Distinctive soft-touch tactile response
Durable barrier with higher cosmetic sensitivity
Recommended for:
Deluxe editions, Kickstarter premium tiers, and boutique game releases.
Linen Finish (Embossed Texture)
Linen finish introduces a micro-embossed texture that mechanically reduces surface contact between cards.
Rather than relying solely on coatings, this texture improves airflow and separation during shuffling, especially in humid environments.
Engineering characteristics:
Improved shuffle separation
Reduced sticking
Requires specialized embossing rollers during the finishing stage
Recommended for:
Traditional playing cards and shuffle-intensive games.
Glossy Varnish
Gloss varnish applies a thin, transparent protective layer that enhances color saturation and surface smoothness without significantly altering card thickness. This finish delivers a crisp visual presentation and balanced shuffle performance, making it a cost-efficient choice for high-volume production.
Engineering characteristics:
- Enhances color contrast and ink clarity
- Low added thickness, minimal impact on flex profile
- Moderate abrasion and moisture resistance
Recommended for:
Standard board game cards, mass-market decks, and cost-sensitive projects.
Matte Varnish
Matte varnish provides surface protection while reducing light reflection, improving readability under strong tabletop lighting. Unlike lamination films, varnish maintains a more natural paper feel while offering basic resistance to scuffing.
Engineering characteristics:
- Non-reflective visual finish
- Preserves paper texture
- Lower surface hardness than lamination
Recommended for:
Strategy-heavy games and designs prioritizing legibility over gloss.
Glossy Lamination
Gloss lamination encapsulates the card surface with a polymer film, significantly increasing durability and moisture resistance. This finish delivers smooth shuffle behavior and high visual impact, particularly for artwork-driven decks.
Engineering characteristics:
- High abrasion and moisture resistance
- Low friction coefficient for smooth shuffling
- Increased card stiffness depending on film thickness
Recommended for:
Playing cards, party games, and decks with frequent shuffling.
Matte Lamination
Matte lamination uses a polymer film to control glare while improving surface hardness and edge durability. Compared to matte varnish, lamination offers superior protection but slightly higher shuffle friction.
Engineering characteristics:
- Strong surface protection
- Reduced glare under overhead lighting
- Slightly increased handling resistance
Recommended for:
Premium board games and collector-oriented products.
Embossing(Raised Surface Detailing)
Embossing mechanically raises selected design elements above the card surface using precision metal dies. This process creates tactile highlights that enhance both visual hierarchy and brand recognition without relying on ink thickness or surface coatings. Embossed elements remain physically present throughout the card’s lifespan, ensuring that logos, symbols, or focal graphics do not fade or flatten with repeated handling.
Engineering characteristics:
- Raised texture formed during die-press stage
- Requires controlled paper recovery and coating compatibility
- Best applied before lamination or combined with soft-touch films
Recommended for:
Card backs, logos, suit symbols, and premium branding accents where tactile visibility is desired.
Debossing (Recessed Surface Detailing)
Debossing presses selected artwork into the card surface, creating a recessed impression that adds subtle depth and refined texture. Unlike embossing, debossed elements sit below the surface plane, offering a more understated and elegant tactile response. This technique is particularly effective when paired with matte or soft-touch finishes, allowing light and shadow to naturally define the recessed areas without visual clutter.
Engineering characteristics:
- Recessed texture formed via reverse die pressure
- Maintains flat surface edges for smoother stacking
- Requires precise pressure control to avoid fiber cracking
Recommended for:
Minimalist designs, luxury decks, and card faces where restrained texture enhances sophistication without affecting shuffle performance.
Can’t find what you want? Contact us!
We’re always happy to discuss new formats or unusual specifications. If you don’t see what you’re looking for above, get in touch. Our team will be glad to help.
Custom board games possess
At Funway, board game production is managed as an integrated manufacturing system, not a collection of independent components. From early-stage consultation through engineering review, sampling, and mass production, each project is supported by a dedicated manufacturing team that works closely with your specifications, files, and component decisions. This consultative approach ensures that design intent remains manufacturable as the project moves from custom board game prototype to mass production.
Rather than treating manufacturing as a handoff after design, we coordinate decisions across the board game supply chain—component definition, tooling release, sampling approval, and production sequencing—to reduce variance, prevent late-stage rework, and maintain consistency throughout production.
Die-Cutting Accuracy & Edge Durability Control
Card cutting quality directly determines deck uniformity, shuffle performance, and long-term durability. We treat die-cutting as a single integrated engineering process—controlling dimensional accuracy, cutting geometry, and edge structure in one coordinated system.
Dimensional Tolerance & Deck Uniformity
Consistent card dimensions are critical for fair gameplay and smooth handling, especially in large decks.
Tight Size Tolerances: In each production run, card length and width are controlled within ±0.35mm to prevent deck misalignment, uneven stacking, or fit issues with tuck boxes and cellophane or shrink wrapping.
Deck Height Stability: Accurate thickness and size control ensure large decks remain manageable and compatible with standard tuck boxes and rigid packaging.
All cutting dies are regularly calibrated and inspected to maintain consistency across the full production lifecycle.
Die-Cutting Geometry & Corner Precision
Cutting geometry directly affects shuffle smoothness and wear patterns.
Optimized Corner Radii: Standard options include 3mm, 4mm and 5mm, and custom radii selected based on card size, thickness, and intended shuffle style.
Wear-Reduction Design: Properly engineered corners minimize edge catching and significantly reduce premature corner whitening during riffle and overhand shuffles..
Edge Locking (Fiber Compression) Process
To enhance long-term durability, we offer an optional edge locking (fiber compression) process during die-cutting.
Reduced Edge Fraying: Compressed fibers resist fuzzing, splitting, and delamination caused by repeated handling.
Improved Moisture Resistance: Sealed edges limit moisture penetration into the card core, extending card life in humid or high-use environments.
This process is strongly recommended for party games, competitive card games, and decks designed for frequent, aggressive shuffling.
Cost Drivers & MOQ Optimization
Unit cost for custom playing cards is primarily determined by a small set of controllable production variables. Optimizing these factors early allows publishers to balance premium feel with manufacturing efficiency.
Core Material Selection
Black core paper carries the highest cost due to its dense, light-blocking structure. Blue and white core options offer strong performance at lower cost tiers, while gray core and C2S are specified for budget-driven projects.
Deck Size & Card Count
Standard 54-card decks achieve the highest production efficiency. Custom card counts are fully supported, though non-standard quantities may affect material yield and per-unit cost.
Special Finishing Effects
Processes such as full-face foil film, spot UV, embossing, or gilded edges require additional production passes and tooling, directly increasing unit price. These effects are typically reserved for deluxe or collector editions.
Packaging Complexity
Tuck box materials, internal printing, custom seals, and specialty papers influence both material and assembly costs. Simplified packaging improves MOQ flexibility, while premium packaging elevates perceived value.
FAQ
Contact
Launching a custom board game can be a complex and challenging process, involving dozens of decisions. We’re committed to making your board game design, printing, and manufacturing process as easy and convenient as possible. But if you have any further questions, please feel free to contact me.
We’re happy to answer all your questions about custom board game printing and manufacturing and can provide you with a quote tailored to your requirements without any obligation. Feel free to contact us—we’re always here to help!
