Rounded corners add an extra production step beyond standard printing, which affects both cost and timeline slightly. Let’s walk through exactly what happens.
The Standard Process First (For Comparison)
Normally, business cards are printed on larger sheets, then cut down to their final rectangular size (typically 3.5 x 2 inches) using a straight-blade cutting process. This is a fast, standard step in nearly every print job.
What Changes With Rounded Corners
After the standard rectangular cutting is complete, rounded-corner cards go through an additional die-cutting pass specifically to round each corner. This uses a curved blade or die shaped to trim a consistent, smooth arc at each corner of the already-cut card.
Why This Adds Time and Cost
- It’s a separate production step, not something that happens simultaneously with the initial cut — meaning your cards physically pass through an additional stage of the production process
- It typically requires its own equipment or die setup, distinct from the standard cutting equipment used for straight edges
- Because of the extra step, rounded-corner orders often take slightly longer to produce than standard square-corner orders, and usually carry a modest additional cost
Does It Affect Print Quality?
No — rounded corners are purely a post-print, structural modification. They don’t affect how your design prints; they simply change the final shape of the already-printed, already-cut card. Your colors, resolution, and overall print quality remain unaffected by this step.
A Design Consideration Worth Knowing
Because the corners are being trimmed into a curve, it’s worth keeping any design elements (like a border or corner graphic) slightly clear of the very corner area — if a design element runs right up to the corner point, the rounding process could clip part of it in a way that looks unintentional. Most templates account for this automatically if you’re using a rounded-corner-specific template from your printer.
What to Expect Cost- and Time-Wise
While specifics vary by printer, expect rounded corners to add a modest fee (often in the range of a few extra dollars for a standard-size order) and potentially a day or so to your overall turnaround time, compared to an otherwise identical square-corner order.
The Bottom Line
Rounded corners are a straightforward, well-established finishing option that adds one extra die-cutting step after standard printing and cutting. It’s a purely structural change — your print quality stays the same — but it does mean a small additional cost and slightly longer turnaround compared to standard square corners, which is worth factoring in if you’re on a tight deadline.
