This project began when Legami, an Italian brand, discovered our original “Fall in Love” couples conversation card game at a trade show. The concept caught their attention, but they wanted to transform it into a more premium product with:
- Thicker cards
- Upgraded packaging
- FSC compliance
The challenge was not simply to manufacture the game. We needed to find the right material solution, meet the client’s environmental compliance requirements, optimize production costs, and maintain the premium positioning they expected.
The result was a successful first order of 12,448 sets.
Table of Contents
Project Overview
The product is a couples conversation card game designed to encourage deeper communication between partners through a series of thoughtfully prepared questions.
Rather than positioning it as a standard deck of cards, the client wanted the finished product to feel more like a premium gift item, particularly suitable for seasonal occasions such as Christmas and Valentine’s Day.
Key Product Specifications
- Card material: 400gsm white card laminated together
- Target card thickness: 1.0 mm
- Packaging: Cylindrical box
- Finishing: Gold foil stamping
- Certification requirement: FSC traceability
- First order: 12,448 sets
Two requirements quickly became the focus of the project: achieving the desired card thickness and satisfying the client’s strict FSC documentation requirements.
Challenge #1: Increasing the Card Thickness to 1 mm
Our original “Fall in Love” version used 300gsm white card laminated together, producing a finished thickness of 0.87 mm.
For many card games, this would already provide a substantial card structure. However, the client specifically requested a thickness of around 1.0 mm; they wanted the cards to feel noticeably thicker and more substantial in the hand.
Instead of simply telling the client that a thicker material should work, we decided to verify the solution physically.
Our Solution: A Free 400gsm Card Sample
We proposed upgrading the cards from 300gsm to 400gsm white card laminated together.
To remove uncertainty before the client committed to production, our team immediately prepared a free blank sample using the proposed material construction.
The sample reached approximately 1.0 mm in thickness, matching the client’s target.
We then sent the physical sample to the client for evaluation.
This allowed the client to confirm the actual thickness, stiffness, and hand feel rather than making a decision based only on specifications provided through email.
Challenge #2: Meeting Strict FSC Traceability Requirements
The second challenge was more complicated.
As a European brand, the client had strict requirements regarding FSC-certified materials and documentation.
Providing our FSC certificate alone was not sufficient.
The client required traceability further upstream in the paper supply chain, including information related to both the paper supplier and pulp supplier.
They also required:
- Company names in English;
- Relevant FSC certificate numbers;
- Supporting certification information;
- Multiple signed declaration documents.
This turned what might normally be treated as a simple certificate request into a supply-chain traceability task.
For an international brand, especially one selling into the European market, incomplete documentation could potentially delay approval even if the physical product itself met the required quality standard.
Our Solution: Tracing FSC Information Through the Supply Chain
Our team worked backward through the material supply chain instead of stopping at our own documentation.
We contacted the relevant upstream suppliers and collected the required FSC information for the paper and pulp supply chain, including the corresponding certification details requested by the client.
The information was then organized and submitted for the client’s review.
This was an important part of the project because compliance is not something that should be addressed only after production has started.
By resolving the FSC documentation requirements before mass production, we helped reduce the risk of compliance-related delays later in the project.
The client subsequently confirmed satisfaction with the documentation we provided.
Cost Optimization: One Small Design Optimization Reduced Foil Stamping Costs
During our review, we noticed an opportunity to optimize the card design.
We recommended using a common back design across all cards.
Why does this matter?
Foil stamping normally requires a dedicated stamping plate. If multiple card backs use different foil designs, additional plates may be required, increasing tooling costs.
By standardizing the back artwork, one foil stamping plate could be used for all card backs.
This reduced unnecessary plate-making costs while preserving the visual effect the client wanted.
From a Standard Card Game to a More Premium Gift Product
Through these adjustments, the final customized version achieved a noticeably more premium specification than the original product that attracted the client at the trade show.
Original vs. Customized Version
| Item | Original Version | Customized Version |
|---|---|---|
| Card construction | 300gsm white card laminated | 400gsm white card laminated |
| Approx. thickness | 0.87 mm | 1.0 mm |
| Product feel | Standard premium card | Thicker, more substantial feel |
| Packaging | Original configuration | Premium cylindrical box |
| Finishing | Standard | Gold foil stamping |
| Sustainability documentation | Standard project requirements | Detailed FSC supply-chain traceability |
| Production optimization | — | Common card-back design to reduce foil plate costs |
Together, these changes made the product more suitable for important seasonal sales occasions such as Christmas and Valentine’s Day.
The Result: 12,448 Sets for the First Order
After reviewing the physical sample, quotation, and FSC traceability information, the client confirmed the project and placed an initial order for 12,448 sets.
The project has now entered the production stage and is expected to proceed according to the planned delivery schedule.
More importantly, the project demonstrates what custom game manufacturing often requires beyond printing.
The client came to us with clear expectations around quality and compliance. Our responsibility was to translate those expectations into practical manufacturing decisions:
- 0.87 mm wasn’t thick enough → we tested a 400gsm laminated construction and achieved approximately 1.0 mm.
- Basic FSC documentation wasn’t enough → we traced certification information further through the paper and pulp supply chain.
- Premium foil finishing increased production costs → we recommended a common-back design to reduce unnecessary stamping plate expenses.
Each solution addressed a specific concern without compromising the client’s premium product positioning.
The client’s first order of 12,448 sets was an important milestone and reflected their confidence in our sample quality, quotation process, documentation support, and overall manufacturing solution.
