So, you’re thinking about making metal cards and want to get the thickness just right not too heavy, not too flimsy, and definitely looking awesome? Let’s walk through the ins and outs of stainless steel, aluminium, and brass cards, with thicknesses of 0.3, 0.5, and 0.8 mm. We’ll cover what each material feels like, how it ages, and what it says about your brand (and your budget).
Stainless Steel: The Heavy Hitter
Why choose stainless steel?
Super durable, so your card feels premium and solid
Resists corrosion (no “rusty card” moments)
Stays rigid even when it’s thin
What does it feel like?
Feels hefty in the hand people notice the weight
A little flex if it’s thin, but nothing dramatic
Cool, modern, and kind of “techy” in appearance
Other stuff to know:
Different stainless grades = different finishes and resistance (if you want it shiny, matte, or somewhere inbetween, you’ll need to pick the right alloy)
Plays nicely with all sorts of coatings and printing
Has a selfhealing surface (thanks to a chromium layer) that fights stains
Best for: Brands aiming for a luxury or hightech vibe, or if you want your card to last forever.
Curious how thick these cards can be? Check out this guide on metal card thickness for more details.
Aluminium: Lightweight Champ
Why pick aluminium?
Super light barely adds any weight to your wallet
Great for people who hate bulky pockets
Naturally resists corrosion (it forms its own protective layer)
In the hand:
Feels light but not “cheap” still has a metallic snap
Easy to slide in and out of card slots edges stay crisp
Won’t weigh down even the slimmest wallets
Things to watch out for:
Thinner aluminium cards can bend if you’re rough
Might show scratches sooner than steel or brass
Needs a good coating to stay looking sharp, especially around the edges
Best for: Tech brands, modern minimalists, or anyone who wants a card that’s easy to carry daily.
Brass: The Classic Showstopper
Why go brass?
Has that warm, golden look stands out from the silver crowd
Easy to shape and engrave, so you can get creative with finishes
Ages with a patina (think vintage, not wornout)
How does it feel?
Heavier than aluminium, lighter than steel a nice “inbetween”
Solid in the hand, but not a brick
Gets character over time (a plus or minus, depending on your style)
Heads up:
Softer than steel, so it can dent or scratch more easily
Needs occasional polishing if you want it to stay shiny
Coatings help, but patina is part of the brass charm
Best for: Luxury brands, vintageinspired designs, or cards meant to make a statement.
Thickness: 0.3, 0.5, or 0.8 mm Does It Matter?
Quick breakdown:
0.3 mm: Super slim, feels sleek but can flex (especially in aluminium)
0.5 mm: Middle ground feels sturdy without getting bulky
0.8 mm: Maximum presence heavy, bold, and super tough
What changes as thickness goes up?
Heavier materials (like steel) add weight quickly. Even a 0.2 mm increase is noticeable!
Aluminium stays light even when thicker, but will still feel more substantial at 0.8 mm.
Brass gives you that “solid” feel without being overkill.
Think about:
Branding: Thicker = more “premium,” but not always practical
Cost: Thinner cards are cheaper and faster to produce
Usability: Too thick? Might not fit in some card readers or wallets
Cost, Durability, & Everyday Use
How does each metal stack up for reallife use and your budget?
Stainless Steel
Pros: Lasts forever, screams quality, looks highend
Cons: Costs more, heavier to carry, may need tweaks for magnetic cards
Aluminium
Pros: Costeffective, super light, easy to process
Cons: Can scratch or bend, doesn’t feel as “expensive” as steel
Brass
Pros: Unique look, ages beautifully, stands out
Cons: More expensive, can dent, needs a bit more upkeep
Everyday questions to ask:
Will your customers use this card daily or just for show?
Does it need to fit in tight wallet slots or card readers?
How much maintenance are you (or your customers) willing to do?
Branding & Budget: What’s Right For You?
Branding Impact
Stainless Steel: Looks and feels premium. Customers remember it as “the fancy card.”
Aluminium: Modern, minimal, and approachable. Great for startups or techy brands.
Brass: Warm, classic, and instantly memorable. Perfect for boutique or luxury branding.
Budget vs. Perceived Value
Steel: Middleoftheroad price, high impact.
Aluminium: Lower cost, more cards for your money, but maybe less “wow” factor.
Brass: Highest perceived value but also highest material and finishing costs.
Tip: Don’t just go for the cheapest material. Think about how your card will make people feel and what that feeling is worth to your brand.
TL;DR: Picking Your Metal Card
- Want “wow” factor and don’t mind the cost? Go with stainless steel or brass.
- Need lots of cards on a budget? Aluminium’s your friend.
- Care about how the card ages? Brass gets a patina; steel and aluminium stay more “as new.”
- Think about thickness. 0.5 mm is a good “safe” bet for most uses, but go thicker if you want presence.
Bottom line: Match your material and thickness to your brand’s vibe, your customers’ expectations, and your budget. And if you’re not sure? Order a few samples your hand will tell you what the spreadsheets can’t!