Free design proof on every custom order: no templates, no stock SKUs
Die-cut flyers are cut to a custom shape rather than a plain rectangle. A rounded corner, an angled edge, or a full contour cut that follows a logo, product silhouette or illustration. The shape becomes part of the design itself, which makes a die-cut flyer stand out on a table or bulletin board full of standard rectangular pieces. Because the cut is custom, it's built around your specific artwork. Tell us the shape you have in mind and we'll work out the die and bleed requirements needed to cut it cleanly.
A standard flyer is trimmed to a rectangle on a guillotine cutter. A die-cut flyer is cut with a custom-shaped steel die instead, which means the outline of the piece can follow almost any shape a designer draws. A rounded card, an angled banner shape, or a full contour cut that traces a product silhouette, a logo, or an illustrated character. The shape isn't decoration on top of the design; it becomes part of the design, which is exactly why a die-cut piece tends to get picked up and looked at twice in a stack of ordinary rectangles.
Because the cut follows the artwork rather than a straight edge, a few things matter more here than on a standard flyer. Fine points and sharp inside corners don't hold up well once trimmed. A die can only cut so tight a radius before the material tears or the corner rounds off slightly in production, so a shape with delicate detail usually needs a small amount of simplification to cut cleanly. A bit of bleed around the cut line also matters more than usual, since even a well-registered die can shift a fraction of a millimeter between sheets, and any gap between the ink and the cut edge shows immediately on a shaped piece in a way it wouldn't on a plain rectangle.
Die-cut flyers work especially well for products or brands with a recognizable silhouette. A bottle shape for a beverage promotion, an animal outline for a pet-related business, a seasonal shape like a leaf or snowflake for a limited-run campaign. They also suit pieces meant to double as something more than a flat handout: a shape that folds into a small stand, or a card with a cutout window that reveals a layer underneath.
Custom dies add cost and lead time compared with a standard trim, since a die has to be made (or an existing one selected, if the shape is common) before the run can print. For a small run, it's worth weighing whether the shape earns its cost against a simpler rounded-corner or notched-corner cut, which gets some of the same visual distinction without a fully custom die. Stock choice follows the same logic as our other flyers. A heavier cover stock, generally 14 pt to 16 pt, holds a die-cut shape's edges better than a lighter sheet, which can feel flimsy once the surrounding paper is trimmed away.
Flyer weight is a signal as much as a specification. Text weights around 100gsm feel like a handout and cost the least per piece, which is right for volume distribution where most pieces are read once and discarded. Cover weights from 250gsm upward feel like something worth keeping, and survive being carried in a bag rather than folded into a pocket. The gap between those two impressions is wider than the gap in price.
Which weight for door-to-door? Text weight. At that volume most pieces are read once, and the saving per thousand is where the budget is better spent.
Full color on one or both sides. The decision worth thinking about is the second side, because it changes what a flyer can do rather than just how it looks: single-sided works when the piece will be seen face up on a table or a windscreen, double-sided when it goes hand to hand and will certainly be turned over. Double-sided costs marginally more and roughly doubles the usable space.
Is the second side worth it? Almost always. The press pass is already happening, so you are buying an entire extra surface for a small fraction of the job cost.
Gloss lifts photographic color and resists handling marks, which suits retail and event promotion where the image is doing the selling. Matte reads calmer and is easier to read a lot of text on, since it does not throw glare under overhead light. Uncoated is the one to choose when anyone will write on the flyer (an order form, a booking slip, a tear-off) because coated stock rejects pen.
Does a flyer need coating at all? For a single-use handout, no. For anything pinned up, carried around, or handled outdoors, it is what stops it looking tired within a day.
Most flyers are a flat trimmed sheet, and the decision is simply size. Adding a fold changes the object into something closer to a brochure. Panels that reveal in sequence, a front that has to earn the opening. Folding also halves the footprint, which matters for anything that has to fit a rack, an envelope or a pocket.
Flat or folded? Flat if everything has to be seen at once. Folded if there is a sequence (a hook outside, detail inside) or if it has to fit somewhere specific.
Rather than a rectangle, the sheet is cut to an outline. A rounded corner, an angled edge, or a full contour following a product silhouette or logo. The shape is a physical tool, so it carries a one-off die cost reused on reprints. What it buys is that the piece does not read as a flyer at a glance, which is most of the battle in a stack of handouts.
Is a shaped flyer worth the die cost? At volume, yes. The die is amortised across the run and reused on reprints. On a few hundred pieces it is a large share of the job.
Ask for samples before committing to a long run. Weight and coating change how a flyer is received more than the design does.
A bonded film rather than a coating. Worth it on cover-weight pieces that will be carried and re-read. It resists creasing at the corners, which is where a handled flyer first starts to look tired.
Cuts glare so long copy stays readable under overhead lighting, and gives a softer surface that reads as more considered. It marks more readily than gloss under heavy handling.
Half, tri-fold or roll fold. A fold turns a flat sheet into a sequence and halves the footprint, which is what lets a flyer fit a rack, an envelope or a pocket without being creased by hand.
A micro-perforated section that detaches. A voucher, a booking slip, a reply portion. It gives a flyer a second life after the first read, which is the cheapest way to make one measurable.
Same family, genuinely different jobs. Your current selection is highlighted.
| Flyer | From | Format | Order it when |
|---|---|---|---|
| Standard Flyers | $180 | 8.5″ × 11″ flat sheet | The default for events and promotion |
| Small Flyers | $170 | 4″ × 6″ postcard scale | Volume, mailing and door drops |
| Business Flyers | $190 | Cover weight, restrained finish | A leave-behind after a meeting |
| Die-cut Flyers | $220 | Cut to a shape | It must not look like a flyer |
| Custom Flyers | $170 | Your size, stock and fold | No standard format fits |
At volume, yes. The die is a one-off spread across the run and reused on reprints, so a repeat order is cheaper. On a few hundred pieces the tooling is a large share of the total and a rounded-corner trim gives much of the effect for less.
Most outlines, though very fine points and deep narrow notches tear during handling rather than holding their shape. We will flag anything at risk on the proof rather than discovering it in the finishing department.
No. Describe the shape or send a sketch and we draw the dieline and show it on your proof before any tooling is cut. If you have one from a previous supplier we will check it rather than redraw it.
Only if it was designed to. An irregular outline can catch or bind, and unusual proportions sometimes attract postal surcharges. If it is being mailed, say so before the die is made.
There is a practical minimum rather than a hard one. Every run carries artwork checks, a proof and a press setup, so a very small quantity of die-cut flyers prices poorly per unit even though we will still make it. If you are ordering a small batch, ask for pricing at two or three quantities at once: the curve usually shows that a modest increase costs very little more in total.
The clock starts when you approve the proof, not when the order is placed, which is the part most people are surprised by. You get a proof first: a digital proof showing artwork against trim and fold lines. On a folded piece the proof shows the panel sequence, which is the only reliable way to check that the right content lands on the panel people see first. Turnaround after approval depends on the finish: anything laminated, foiled or die-cut adds a stage that cannot be compressed without causing problems later. Tell us the date you actually need them and we will work backwards from it rather than quoting a generic lead time.
Yes. Cut to a shape is the standard build, and the dimensions around it are yours to set. A size that sits efficiently on the press sheet often costs no more than a standard one, while an awkward proportion that wastes half the sheet does. Ask before you commit and we will tell you whether a small change to the dimensions saves a disproportionate amount.
In most cases they are the same product under a different name: the trade uses several terms for it depending on the region and the supplier. What actually defines this one is the build: cut to a shape. Order it when it must not look like a flyer. If you have seen it called die-cut flyers printing elsewhere, describe what it has to do rather than which name you found, and we will match the specification.
Yes. We provide free samples, and on die-cut flyers it is worth asking for one, because the difference between text weight gloss and text weight matte is obvious in the hand and invisible on a screen. Most orders run on text weight gloss, but ask for whichever you are weighing up. You also get a free design proof before anything goes to press, so nothing is printed that you have not seen.
The usual choices are gloss lamination, matte lamination, folding. Finish is not decoration on this product so much as a decision about how long it survives and how it reads in the hand, so it is worth choosing against the job rather than the budget. Tell us where the finished piece ends up and we will say which finish is doing real work and which is only adding cost.
Yes, and that is what almost every order here is. Nothing in this catalogue is a stock item: die-cut flyers are manufactured to the specification you give us, with your artwork on them. Send your logo as vector artwork where you have it, since that scales to any size without softening. If all you have is a low-resolution file, tell us and we will say what it needs before it reaches the press.
Yes, and a repeat run is simpler than the first one. We keep your approved specification on file, so a reorder skips the setup decisions and goes straight to production. Where the job used custom tooling, that tooling is reused, which is why a shaped run costs less the second time. Tell us the previous order and we will match it rather than starting the specification again.
Yes. Regalo Print has been producing custom commercial print for businesses across the USA and Canada since 2008, and every order ships tracked. The tracking number reaches you the day the job leaves, not the day it arrives. If you are working to a fixed date, say so when you order so the production schedule is built around the delivery date rather than the other way round.
