Picking the right thickness for your aluminum sublimation blanks is one of the first decisions you'll make — and it matters more than most people think. The thickness affects how the final product feels in hand, how it handles during heat pressing, and what applications it suits best.
At AlumCraft, we offer blanks in 0.22mm, 0.30mm, 0.40mm, 0.50mm, and 0.55mm. Here's what each one does best.
Quick Comparison
At a Glance
0.22mm — Ultra-thin, flexible. Labels, stickers, bookmarks.
0.30mm — Thin, slightly bendable. Lightweight tags, ornaments.
0.40mm — Mid-weight. Versatile all-rounder.
0.50mm — Near-standard. Rigid cards with a lighter feel.
0.55mm — CR80 standard. Full credit card weight and rigidity.
0.55mm — The Standard
This is the most popular thickness in the sublimation industry, and for good reason. At 0.55mm, aluminum blanks match the standard CR80 credit card thickness (ISO/IEC 7810 ID-1). They feel substantial in hand — rigid, durable, and professional.
Best for:
- Business cards and executive cards
- Membership and loyalty cards
- Gift cards and store cards
- Badges and ID cards
- Pet tags and luggage tags
This thickness holds up well to daily handling and gives your finished product the weight and feel that customers associate with premium quality.
0.50mm — The Light Alternative
Just a hair thinner than standard, 0.50mm blanks offer a slightly lighter feel while still remaining rigid enough for card applications. Some customers prefer this for large-volume mailers where shipping weight matters, or for products where a softer hand feel is desirable.
Best for:
- Corporate gift cards
- Promotional cards (mailed in bulk)
- Luggage tags and key fobs
0.40mm — The Middle Ground
At 0.40mm, blanks still have reasonable rigidity but can flex slightly under pressure. This is a versatile thickness that works across many applications without being too thick or too thin.
Best for:
- Commemorative medallions and awards
- Photo pendants and ornaments
- Drink coasters (with backing)
- Event name badges
0.30mm — Flexible and Lightweight
This is where the blanks start to feel noticeably different. At 0.30mm, aluminum becomes flexible enough to bend slightly — similar to a thick playing card. It won't spring back to shape like 0.55mm will.
Best for:
- Bookmarks (thin and elegant)
- Ornament hangers
- Product labels (premium metal label feel)
- Wrapping accents and decorative elements
0.22mm — Ultra-Thin
The thinnest option in our range. At 0.22mm, these blanks are paper-thin and highly flexible. They can be cut with scissors and even rolled. The trade-off is reduced durability — they're more prone to denting and bending.
Best for:
- Stickers and labels with metal finish
- Thin bookmarks
- Craft and DIY projects
- Decorative inlays and overlays
How to Choose
Start with the end product in mind. Ask yourself:
- Does it need to feel like a real card? Go with 0.55mm.
- Does it need to bend or flex? Consider 0.30mm or 0.22mm.
- Is shipping weight a concern? 0.50mm saves grams per unit.
- Will it be handled roughly daily? 0.55mm is the most durable.
- Is it a decorative/craft item? 0.40mm or 0.30mm gives you flexibility.
When in doubt, order samples in multiple thicknesses and test them on your heat press. The feel in hand often matters more than the number on the spec sheet.
Want to Feel the Difference?
Ask about a sample plan for comparing suitable thicknesses on your press. Availability, cost, preparation time, and shipping depend on the project and are confirmed in the written quotation.
Discuss Sample Options →