Custom Die-cut Door Hanger
Custom die-cut door hangers in the shape you draw — not a rectangle with a hole — on heavy card, printed both sides, from 100. The die is made once and kept; the dieline and price come back the same working day.
A door hanger that is not a rectangle gets read
- Board
- 14–18pt card, UV coated or laminated
- Builds
- Any die-cut outline; round-hole, keyhole or long-slot hook
- Full color both sides
Get a price for Die Cut Door Hanger
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
The hook slot has to fit every handle on the street
Door handles run from a slim lever to a round knob 60 mm across. The slot at the top of the hanger is cut to fit the largest of them: a 35–40 mm hole with a slit to the edge, or a "keyhole" that opens over a knob and closes behind it. We cut the slot to that standard on every shape, and it is drawn into the same die as the outline.
| Round hole 35–40 mm + slit | Fits most knobs and levers; the default |
|---|---|
| Keyhole | Grips the handle; less likely to blow off |
| Long slot | Lever handles only; not for mixed housing |
Shapes that hang straight
- Keep the mass below the hole — a wide top and narrow bottom swings and shows its back.
- Round every point; a sharp point curls in the rain and catches on a coat.
- Avoid narrow necks between the hook and the body; that is where a shaped hanger tears.
- A shape that reads at a glance beats an intricate outline that needs a second look.
Card weight against weather and wind
Door hangers live outside. 14pt card is the working minimum; 16–18pt if the shape is large or the neck is narrow. A gloss or matte UV coating keeps a shower from making the card go soft, and it is the coating that keeps the print from running on the door. Our door hanger range in standard formats covers the rectangular cards if the shape is not the point.
Both sides, and the tear-off
The hanger is seen from the outside first and from the inside when the door opens, so both faces print. A perforated tear-off at the bottom — a coupon, a business card — is cut on the same die and is the most-used feature on these. Keep the perforation inside the shape so the tear-off is a clean rectangle even when the hanger is not.
A shape with a tear-off needs the mass below the hole after the tear-off is gone. We check the balance both ways.
Who uses shaped hangers
Restaurants and takeaways, real-estate agents, cleaning and lawn services, roofers after a storm, churches and community groups, and hotels for the in-room card. The shape is usually the product or the trade, which is why one die serves a business for years.
Die Cut Door Hanger — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- 14–18pt card, UV coated or laminated
- Builds
- Any die-cut outline; round-hole, keyhole or long-slot hook
- Full color both sides
- Options
- Perforated tear-off, rounded corners, spot UV
- Sizing
- Typically 90–110 mm wide, 200–280 mm tall
- Tooling
- One die for outline, hook and perforation; kept for reorders
- Minimum
- 100 hangers
On every job
- Print process
- Digital below about a thousand, offset above it. Both sides as standard on cards, tags and leaflets.
- Color
- CMYK with spot colors for a brand match. Uncoated and cotton stocks print noticeably lighter than coated ones.
- Tolerance
- Trim plus or minus 1 mm guillotined, plus or minus 0.5 mm die-cut. Anything over about 170gsm is creased before folding.
- Tooling
- A die only where the piece is shaped, perforated or drilled, made once and kept. A plain rectangle needs none.
- Food contact
- Food-safe inks on menus and counter print that will be handled where food is served.
- Sustainability
- Uncoated and unlaminated stocks recycle without separation, and FSC papers are available across the range.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build die cut door hanger on
Sheet print is judged in the hand more than a box is: the weight, the surface and whether a pen works on it. These are the stocks we run for cards, folders, leaflets and stationery.
Coated card 300–400gsm
The workhorse. Sharp full-color print, matte or gloss, laminated where it is handled. Does not take a pen unless the finish is matte.
300–400gsmUncoated card
No clay coat. Colors read softer and warmer, a deboss goes deeper, and it writes on with anything. Photographs lose punch.
300–400gsmCotton and textured card
Soft, thick and fibrous. Takes a deep blind deboss and reads as an invitation. Foil sits beautifully; four-color does not.
400–700gsmDuplexed card
Two sheets bonded, often with a colored core, for a very thick card with a visible colored edge. The heaviest thing we print.
600–900gsmText paper 100–170gsm
Leaflets, folder inners and booklet pages. Folds without cracking and takes a full-color print on both faces.
100–170gsmManila and kraft paper
Unbleached, tan, and cheap. One or two colors read well; white ink gives a light mark. Envelopes, folders and tags.
90–300gsmSynthetic stock
Polypropylene sheet for tags and cards that get wet, torn or handled outdoors. Prints like paper and does not soften.
200–400 micronBoard-backed
A printed face laminated to grayboard, for a rigid card, a folder back or a display that has to stand up on its own.
1–2 mm boardNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Sheet print takes the widest range of finishes of anything we make.
Matte lamination
Soft, fingerprint-resistant, and it still takes a pen. The default on anything handled.
Gloss lamination
Maximum color depth. Shows every fingerprint and refuses a ballpoint.
Hot foil
Gold, rose gold, silver, holographic or a color. The block is small so the die is cheap.
Emboss and deboss
Deepest on uncoated and cotton stocks; shallow and prone to cracking on gloss coated.
Spot UV
A gloss shape on a matte laminate. Best on a dark ground where the contrast reads.
Edge paint and colored core
Color on the cut edge of a thick or duplexed card. Only seen when the card is picked up, which is the point.
Soft-touch
A velvet laminate on a cover or a folder. Marks on white; excellent on dark.
Uncoated and textured
No film at all. Writes on, debosses deeply, and reads as considered rather than cheap.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing printed sheets, folds and the grain: die cut door hanger
A printed piece is specified flat and finished folded, and the difference between the two is where mistakes live. Send the finished size you want and we work back to the flat.
- Finished size
- The size after folding and trimming. A6, A5, A4, DL, US letter and legal are standard; anything else is cut on its own die.
- Bleed and safe area
- 3 mm of artwork past every trim edge, and nothing important within 4 mm inside it. The guillotine drifts by a fraction on every stack.
- Grain direction
- Paper folds cleanly along the grain and cracks across it. We set the grain to the fold, which is why a sheet is not simply cut from the biggest sheet available.
- Fold allowance
- On a roll fold or a gate fold, the inner panels are cut a millimeter or two shorter so the piece closes flat.
- Creasing
- Anything over about 170gsm is creased before folding. Without it the fold cracks and the coating flakes along the line.
- Trim tolerance
- Plus or minus 1 mm guillotined, plus or minus 0.5 mm die-cut.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Spec your Die Cut Door Hanger
Pick a shape, type a size, choose a stock and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about die cut door hanger? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What shapes can you cut?
Any outline that can be die-cut from card: a house, a leaf, a product silhouette, a rounded tag. We advise on necks and points that would tear.
Will it fit round door knobs?
Yes. The hook slot is cut to a 35–40 mm hole with a slit, or a keyhole, which fits nearly every knob and lever.
Will it blow off in wind?
A keyhole hook holds better than a plain slot. Keeping the weight below the hole stops it swinging and showing its back.
What card weight do you use?
14pt minimum, 16–18pt for large or narrow-necked shapes, with a UV coating so rain does not soften it.
Can I have a tear-off coupon?
Yes, perforated on the same die. We keep the coupon rectangular inside the shape so it tears clean.
Is it printed on both sides?
Yes, as standard — the outside is seen on approach and the inside when the door opens.
What is the minimum order?
100 hangers.
Does the die cost extra?
It is a one-off shown on the quote, and it is kept, so every reorder of the same shape skips it.
Is the card weatherproof?
Weather-resistant with a UV coat or laminate, enough for a day or two on a door in rain. It is not a permanent outdoor sign.
Can I change the print but keep the shape?
Yes. The die stays the same; only the print changes.
What size should it be?
Most run 90–110 mm wide and 200–280 mm tall — large enough to read from the path, small enough to hang clear of the lock.
Do you send a proof?
A dieline with the quote, then a proof of both sides on it before press.
Same range
