Custom Round Cardboard
Custom round cardboard discs cut to your diameter — cake circles, tin and jar pads, layer separators — in the board the job needs, from 100. Cutting spec and price the same working day.
A circle of board is a product in its own right
- Board
- Grayboard 1.5–3 mm, E/B flute, white lined chipboard, kraft board
- Formats
- Plain discs, food-grade cake circles, lid inserts, layer pads
- Diameter
- Any, from about 30 mm to 500 mm; ±0.5 mm
Get a price for Round Cardboard
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.
Which board for which disc
| Food-grade grayboard, 1.5–3 mm | Cake circles and boards; white or silver face optional |
|---|---|
| Corrugated E or B flute | Layer pads in a round tin or tube; cheap and cushioning |
| White lined chipboard | Jar and tin lid inserts, cosmetic pads, gift-box floors |
| Kraft board, 300–500 gsm | Light discs, coasters, label backers |
Diameter, tolerance and the fit inside a tin
A disc cut to sit inside a round container needs to be 1–1.5 mm under the internal diameter — enough to drop in, not enough to rattle. A cake circle sits under the cake and is cut to the cake size or 10–20 mm over it. We hold ±0.5 mm on a die-cut circle, which is closer than most tins are made to, so we ask for the tin and cut to it. Our paper tube range for round packaging is where most of these discs end up.
Food contact for cake boards and separators
- Food-grade board with a white or silver-foiled face for cake circles and cupcake bases.
- Grease-resistant face where the disc sits under a buttercream or a pastry.
- Plain kraft and grayboard for discs that touch the container, not the food.
- A glassine or wax-paper face laminated on for chocolates and confectionery.
Say if the disc touches food. Standard grayboard is not food-contact grade; the food-grade version costs little more and is a different board.
Printed discs
A disc is a flat print with no folds, which makes it easy to print well. A logo or a pattern on a cake board, a message on a gift-box floor, a color on a lid insert — full color or a single color, laminated where it is handled. Foil on a round card reads as a coaster or a medallion, and is used that way.
Quantities and how discs are supplied
Discs are die-cut in stacks and supplied shrink-wrapped in counts of 50 or 100. The die is a simple round cutter, made once per diameter and kept, so a bakery that orders three sizes has three dies on file and reorders any of them without tooling.
Round Cardboard — 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
- Grayboard 1.5–3 mm, E/B flute, white lined chipboard, kraft board
- Formats
- Plain discs, food-grade cake circles, lid inserts, layer pads
- Diameter
- Any, from about 30 mm to 500 mm; ±0.5 mm
- Face
- Plain, white, silver foil, grease-resistant or glassine-laminated
- Full color or single color; foil on request
- Supply
- Shrink-wrapped stacks of 50 or 100
- Minimum
- 100 discs
On every job
- Print process
- Flexo in one to four colors straight onto the liner; litho-lamination where the box needs full color or a photograph.
- Color
- Flat colors on kraft. Full color needs a white top liner or a laminated sheet, because brown shifts every color warm.
- Tolerance
- Cutting plus or minus 1.5 mm. The flute compresses, so corrugated runs wider than folding board.
- Tooling
- No die on a regular slotted box, which is cut on a slotter. Die-cut mailers and trays need one, made once and kept.
- Food contact
- Food-grade liners and a vented build where the box carries hot food.
- Sustainability
- High recycled content through liners and flute as standard, and the box recycles whole if it is sealed with paper tape.
- 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 round cardboard on
Corrugated is a fluted sheet glued between two liners, and the flute decides nearly everything: how it prints, how it dents, how high it stacks. These are the grades we run.
E flute
About 1.5 mm. Prints well and folds crisply; dents under a stack. Retail boxes, mailers and light shippers.
1.5 mm, single wallB flute
About 3 mm. The working default for parcels — takes print reasonably and stacks reasonably. Most shipping boxes are B.
3 mm, single wallC flute
About 4 mm. More cushioning than B, slightly less stacking strength per weight. Common on grocery and produce cases.
4 mm, single wallBC double wall
B and C glued together, about 7 mm. Heavy or fragile goods, pallet stacking, anything over roughly 15 kg.
7 mm, double wallKraft liner
Brown, strong, absorbent. One or two flat colors flexo print well on it; photographs drink into the brown and go muddy.
Outer and inner linerWhite top liner
A bleached outer liner for full-color print on corrugated. Costs more and marks more easily than kraft.
Outer liner onlyRecycled-content corrugated
High post-consumer fiber through liners and flute. The default for shippers; a slightly greyer brown and no loss of strength at grade.
All flutesCoated and water-resistant
A coating or a wax-free barrier liner for damp stores and cold chains. Check the recycling stream before printing a claim on it.
B and C fluteNot 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.
Corrugated takes fewer finishes than folding board, and the ones it takes it takes well.
Flexo on kraft
One or two flat colors straight onto brown. Cheap, fast, honest.
Litho-lamination
An offset sheet glued to the flute: full color and photographs on a shipper.
Aqueous varnish
Scuff resistance with no film, so the box still recycles whole.
White top print
Full color flexo on a bleached liner; brighter, and it marks more easily.
Inside print
A second pass on the inner liner — the panel a customer sees first.
Printed tape seal
The brand applied at the last moment, on paper tape that recycles with the box.
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 a corrugated box against the carrier, not the catalog: round cardboard
Corrugated is cut to your internal size, so the box goes round the product rather than the product going into a stock size. That is where the money is: a box 20 mm smaller each way is often a whole postage band cheaper.
- Internal dimensions
- Length, width and depth of the space you need. Board thickness is added outside that, and the flute is thicker than people expect.
- Clearance and void fill
- 5–10 mm a side for a rigid product. Size it properly and you need no void fill at all, which is cheaper and better received.
- Stacking
- Tell us how high the boxes stack on a pallet or a shelf. Edge crush grade is specified from that, not guessed.
- Weight
- The contents weight sets the flute and the liner grade. Over about 15 kg we move to double wall.
- Score allowance
- Corrugated needs more room at the folds than boxboard. The dieline accounts for it; a box drawn from flat dimensions comes out tight.
- Cutting tolerance
- Plus or minus 1.5 mm on corrugated, wider than folding board because the flute compresses.
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
Build your Round Cardboard in 3D
Pick a shape, type a size, choose a board 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 round cardboard? 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 sizes of round cardboard can you cut?
Any diameter from about 30 mm up to 500 mm, held to half a millimeter. Send the size or the container and we cut to it.
Are your cake circles food safe?
The food-grade version is, with a white or silver face and a grease-resistant option. Standard grayboard is not, so tell us if the disc touches food.
How much smaller than the tin should the disc be?
About 1–1.5 mm under the internal diameter, so it drops in without rattling. We prefer to cut from the tin itself.
Can the disc be printed?
Yes. It is a flat print with no folds, so full color, single color and foil all work well.
What board thickness do you use?
1.5–3 mm grayboard for cake boards, E or B flute for cushioning pads, thinner board for lid inserts and label backers.
What is the minimum order?
100 discs per size.
Do you keep the die?
Yes, one per diameter, so reorders skip the tooling.
Can I have a silver cake board?
Yes, a silver-foiled food-grade face is a standard option.
Can discs be used as layer separators?
Yes, in tins, tubes and round boxes, usually in E flute or thin grayboard.
How are they packed?
In shrink-wrapped stacks of 50 or 100, flat.
Can you cut other shapes?
Yes: ovals, hexagons, scalloped edges. Each is its own die.
Do you ship outside the US?
Yes, to the United States, United Kingdom, Canada and Australia, quoted in the delivery currency.
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