Why do my business cards crack around the edges
Edge cracking can occur on business cards with heavy ink coverage, particularly cards with dark colors that cover most of the surface. The thick layer of ink becomes less flexible than the paper stock, so when cards are cut or handled, small cracks may appear along the edges.
This typically affects only a small number of cards in a run. To minimize cracking, use lighter colors where possible, or if you need dark colors, try to reduce the total ink density. Matte or uncoated finishes are also less prone to cracking than UV-coated cards.