I have about 500 sheets of cardstock to turn into door hangers, and I need a clean 1.25-inch hole in each. I found a punch for that size, but would rather not buy a tool I may only use once. Would clamping the sheets and using a hole saw work, or is there a better option?
What’s the cleanest way to make 1.25-inch holes in 500 sheets of cardstock?
Asked by QuietPebble
Answers
Before buying anything, ask a local print shop or copy shop what they’d charge to punch the stack. They may already have equipment meant for paper, and for a one-off batch the time and cleaner finish could be worth more than owning another tool.
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A regular hole saw is a gamble on cardstock. It can snag or tear the fibers, and heat can be an issue. If you want to do it yourself, look for a paper drill bit made for drilling stacks, or a sharp round punch paired with an arbor press. Those are much better suited to getting a neat cut through multiple sheets.
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I wouldn’t clamp all 500 sheets and go at them with a hole saw. Even if the stack stays put, that’s a lot of material for a conventional saw to cut cleanly. A purpose-made punch is the straightforward option, but you could also check whether a suitable punch and press are available to borrow or rent. Test your setup on scrap first, especially if the sheets are already printed.
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