After reading this post, a MakerWorld user reached out to me and asked if I would share the method I use to make playing cards, so I’m going to share that process here in the event that anyone else would like to know.
I would highly recommend using a 0.2mm nozzle, even if your design isn’t that intricate. A 0.2 nozzle is just better quality.
I use a 0.1mm layer height and design my cards to be five layers total. Two layers for the card back colour/design, two layers for the card face colour/design, and the middle layer has to be black. The reason for the five layers is because one layer for each of the card back and card face just isn’t enough. Imperfections show through and colours aren’t as vibrant, so two layers per side are needed.
The fifth layer is in the middle and has to be dark, preferably black. You can get away with not using this layer if your card back is a solid black colour, but if you intend to put some sort of design in another colour on your card back, you will need to add a black layer in the middle to prevent light from bleeding through, making your card face visible through the back.
In the following picture you will see two cards, both 0.5mm thick with just one difference. The card on the right has a purple middle layer and the card on the left has a black middle layer. You can clearly see a horseshoe through the back and the words “Lucky Charms” through the face on the card without a black middle layer.
Also, when you’re designing your cards, split all of the different colours into different pieces
Then export that (put back together) as a stl and open it in Bambu Studio. Right click on the card, select Split/To Parts and colour the parts appropriately.
Optional bonus points if you use the 3D Effect Plate to add a little extra to your card back design. I used the galaxy sheet on my Lucky Charms deck and I love it. Not just for the galaxy effect, but for the overall glossy, almost laminated look to the card back. It’s a level of smooth that I would never have thought possible with FDM printing. These photos don’t do it justice.
@Makers_Supply Please consider adding an effects sheet that has no sparkly effect, but still leaves your print with the glossy, hyper smooth surface that the current 3d effects sheets produce.
@MakerWorld Please consider adding a Make-My-Playing-Card tool to the MakerLab.