Custom Pin Backing Cards: Sizes, Hole Placement & Packaging

A Canadian retail project: the text at risk was on the reverse

An independent Canadian creative-goods retailer was buying polished imitation enamel pins for its physical shop, with paper backing cards and transparent OPP bags.

The initial layout used 250 gsm white cardstock, with brand text close to the mounting area. Our artwork review flagged two risks: the butterfly clutch base could cover text on the reverse, and the proposed card stock needed a closer look at how it would support this particular pin. The concern was that the assembled card might bend backward and present poorly on the shelf. These were risks identified before production.

We adjusted the relative positions of the holes and artwork to leave room for the clutch base, and changed the stock to 350 gsm coated cardstock. An inward-curving, crescent-shaped relief slit was also die-cut into the same sheet below the circular opening. This local clearance adjustment was intended to reduce cutting contact from the clutch base and concentrated pulling around the opening. It added no patch, folded support or separate assembly step.

After the layout was settled, we made a backing-card sample and fitted it with a real pin. The checks focused on readable reverse-side text and how well the card stayed flat. The customer signed off on the assembled sample before bulk card printing began. The pins and cards were supplied together in bags; feedback from the shop was that the cards stayed flat and the artwork remained visible in the retail display.

The useful lesson is to review the pin face, reverse hardware and card stock together. The 350 gsm stock and relief slit were choices for this project; another pin and card combination needs its own sample check.

Choose the display method before the card size

Shop retail, online orders and event distribution place different demands on a backing card. Retail may need a price, SKU label or hang hole. Event handouts may put more emphasis on explanatory copy, counting and easy handling. Explain the destination first so the supplier knows which areas must remain usable.

Start with an actual-size layout. Place the pin outline on the proposed card, then check three sets of space:

On a small screen, swipe the table sideways.

A larger card usually offers more room for artwork, but also changes the bag size, display footprint and carton packing. If several pin designs share one card, check the outline and post positions of every design against it.

Position mounting holes from the actual posts

The geometric center of the artwork is not necessarily where the post belongs. Attachment placement has to consider balance when worn, the intended orientation and a solid metal area where the post base can be fixed. Irregular, heavier or cutout designs may need an off-center position or two separated posts. Mark the card from the confirmed post count, positions and clutch footprint.

Keep pin mounting holes separate from a retail hang hole: the first secures the pin; the second fits the display hook. Identify both on the drawing where needed. A horizontal bar pin or brooch mechanism also needs a card arrangement that suits how it opens and closes.

For hook displays, decide whether the card or the outer bag provides the hanging point. If you use a hole in the card, the card must be exposed or the bag construction must allow the hook to pass through. A card sealed completely inside an ordinary flat OPP bag can still have its hang hole blocked by film. With a clear hanging bag that has its own hang-hole header, check the header and seal positions against the logo at the top of the card. Try the complete packed item on the intended hook: it should hang, be easy to take down and keep the branding visible.

Check the pin’s footprint on the front and the clutch bases plus removal space on the reverse. For two-post pins, confirm spacing, orientation and room to fasten both clutches. When a hole moves, review the front again to make sure the pin still sits in the intended position.

The printer’s proof should show both sides, actual post locations and the areas occupied by the hardware. Keep copy, QR codes, barcodes and retail labels usable after assembly. Confirm bleed, cutting safe areas and front-to-back registration with the selected printer.

The references below show different attachment arrangements. Confirm the fit and safe closure of the mechanism you actually order.

Choose cardstock by its assembled behavior, too

“250 gsm” and “350 gsm” describe mass per unit area, not a card’s thickness or load capacity. Stock type, caliper and fiber direction also affect how stiff it feels. Holmen Board and Paper’s technical information treats grammage, thickness and stiffness as separate properties.

If you buy cardstock by thickness in points (pt), ask the printer to provide both grammage and caliper, with units. A 250 or 350 gsm specification does not convert into a fixed 14pt or 16pt thickness.

In the Canadian project, 350 gsm coated cardstock worked with the revised layout and was accepted after an assembled sample review. For another project, ask for candidate stocks and compare flatness, feel and print appearance with the actual pin attached.

Give support particular attention for a heavy or wide pin, or several pins on one card. A lighter pin, a short handout period or support from an outer box may make a lighter stock worth evaluating. Thicker stock can change cost, packed thickness and the post length available for clutch engagement. If you add lamination, layers or another support, check the final combination: enough post must remain exposed for the clutch to engage fully.

Review the material around openings on a sample as well. The Canadian project used a local crescent-shaped relief slit; another card needs a fresh assessment of stock, hardware and opening shape. Check the cut position and remaining material for any new weak point.

Approve a complete assembly before bulk card printing

An actual-size paper mockup is useful for proportions, text and layout. Stiffness, clutch engagement and bag fit need a further check with the proposed card stock, real pin and actual clutch.

Bring these checks into the same sample review:

On a small screen, swipe the table sideways.

Select representative combinations for singles, sets and designs with noticeably different post layouts. Agree separately on any longer display period, repeated handling or transport evaluation that the project needs.

The approval record should identify the card artwork version, stock, pin and clutch, packaging and approval status. This gives both sides the same reference when the job moves from sample to bulk production.

Copy a backing-card RFQ brief

Fill in the details you know. Use “To be confirmed” for decisions still open, and ask the supplier to separate printing, die cutting, carding and bagging.

Use and display: [shop retail / online orders / event distribution; describe the display].
Pins: [dimensions, quantity by design, post count and post-position information].
Backing card: [finished dimensions, front/reverse artwork versions, stock type and gsm, caliper requirement and surface finish].
Mounting and hanging: [pin mounting locations; hang from the card or bag header; how the bag and seal work with it].
Keep-clear information: [brand, copy, SKU / barcode / QR code and label areas].
Delivery scope: [factory-mounted or separate components; individual bags, labeling and sorting by design].
Please itemize printing, die cutting, assembly, packaging and sample charges. Provide a complete assembled sample for approval before bulk production.
Destination and required arrival date: [country / postal code / date].