So after reading this closed post about printing cards in small runs I thought some info I just gained from a card and board gaming buddy might be useful to other folks than me. So here's two methods I've just learned about that are be used by some indie board game and card makers here in Madison. I apologize for not having enough details about the indie companies, cost, etc. I'll see if I can expand on my knowledge by asking around some more. Anyway....

The first is a guy who made a set of around 200 decks that have approximately 30 cards per deck. They are normal sized playing cards. What he did was to make a postcard that had the art for two cards on it. He then went to a postcard printer and had them print the postcards. He then bought a die that is the size of a card and used a press that a local library lets folks use and cut the cards out. The cards are pretty decent and the game has really good production quality. He'll save money on his next run since he already owns the die.

Another solution I heard about recently was some guys who are printing their cards on cardstock like what you might have in war games for unit markers, or in board games for pieces. They then take the cardstock to a place that does laser cutting and have the cards cut out in the shapes they want with lasers. This makes it so you don't have the small hanging chad like you would with cardstock game pieces you punch out yourself.

If anyone knows any alternative methods for making D.I.Y. cards I'd love to hear them.

Your first method is similar to how I produce my Final Twilight card game. I can't add much to that, except for some finishing touches:
- Larger postcards, while more expensive per unit than 4x6's, can fit more cards and drop the actual cost per unit. Is a good thing. I use 5 1/2 x 8 1/2, 4 cards per postcard as opposed to 2.
- If you don't have a card press, desktop edge rounders work out nicely for the rounded edges. A local print shop can do the cutting from the larger card.
- I use BCW Plastic Cases for packaging, with a paper insert for the front and back. With a resellers account through BCW, its cheaper than getting limited runs of boxes printed and assembled.

Any chance you could find out where your friend found the die? I've been looking for one myself to no avail.

Nate, are you looking for a die for a big press, or something you can use in your home?

Most tool and die companies can actually create a die for you.  Plan on spending $500.00+ on the die easy (last I checked).  Definitely get specs on the press you are planning on using it on to make sure that you don't have an expensive die that won't work on your press.

Next, I recommend the Accu-Cut Grand Mark line of home cutters.  You can custom order a die that can cut out multiple cards simultaneously.  If you order a custom die, then make sure you ask to see if they can put in a stop or something else to help you line up a PRE PRINTED CARD.  Say those words.  A lot of people who use these machines are scrapbookers and the like, and they work on unprinted materials or do just one thing at a time.  The machine plus the die is probably gonna run you $500 - $700 and this type of die won't work on an industrial die press machine.

Our card game, Zombie Rally, is in the orginial Cheapass Games style seen in the original Give Me the Brain. Black ink offset printed on mint green colored cardstock and trimmed with a normal electric trimmer at the print shop, no rounded corners. We went with a local printer here in town and cranked out 500+ (there's always overruns) decks of 54 cards each for $480 or so, which included 500 of the instruction sheet (half an 8.5x11 inch sheet of thin white paper cut the long way). Instead of 5x8 inch white paper envelopes with black printing on the front like the old Cheapass games, we bought poly zipper bages from Associated Bag in Milwaukee. Then we had a 4.25x6 inch color postcard full color offset printed from Growll and had one full color cover card printed on each half, and then had them trimmed so we got two. Click the Zombie Rally link above to go to the page on our web site and see a big photo of the game and its contents.

Your local print shops can do a lot of work that you might not think. Always work closely with your printer to make both your lives easier. If your game has to be in full color or has to only be printed in runs of 50 to 100, then your local print shop may not work. But newer, smaller four or six color presses are becoming the norm, so check your local print shop.

Ask me if I can help any further.

Nate: I don't know the exact name and dimensions of the die but I'm told he purchased it from Ellison. I don't actually know the creator well, I'm getting the info from a mutual friend who was showing me the finished product, and I was asking him questions as I may have cards in the game I'm working on. If you aren't able to find what you are looking for via Ellison, PM me about it, and I'll try getting more info from the designer. Option two would be to cut my sorry butt out of the loop and message the designer directly via Goadrich Games.

This Program, Nandeck, looks like it may be really useful. It helps you with designing decks, sizing up the cards so you can get them the right size to layout on paper for printing, etc. I've only had a little time playing with it, but so far it looks really useful for making cards. It uses windows, and is not all point and click, it will require you to learn a bit of commands that are about as easy to pick up as basic HTML.

According to Ellison, they've got a playing card die for $25: http://www.ellison.com/shop/?p=product_detail&itemnum=22588

-Thomas

Not so much DIY, but certainly cheap and affordable - Avalon Innovations, a good POD printer, have recently started doing POD cards and card boxes. Not tried them yet, but their prices seemed very good with little to no setup costs.

Card threads and the book binding threads are always really interesting but I've delurked because I want to make sure I follow.

With a  card die like this one  http://www.ellison.com/shop/?p=product_detail&itemnum=22750

and a press like this one http://www.ellison.com/shop/?p=product_detail&itemnum=19356

you could cut your own cards at home... but you'd be doing them one at a time right?

Thanks,

Tony

You'll really need to spend money on a custom die with Ellison if you are doing any volume at all.  You will want a die that cuts out a page of cards at once, not one card at a time.  Also, make sure whether you are getting bridge or poker-sized dies.

In a previous post in this thread I quoted the price range you can expect to pay for both a custom die and the die press.