While working at SEOmoz I was tasked with designing our corporate business cards. This was always terribly frustrating, not because of any wrongdoing on their part, but simply because I was always unhappy with how the cards turned out. I have very little experience with print design, and somewhere along the way my designs would always end up looking terrible in print. The type would look distorted, the colors were always off, and I even had several cases where elements came out improperly aligned when I got them back from the printer.
With pubcon coming up, I wanted to make some new business cards for myself that were unique, memorable, and looked good. I also didn't want them to be a standard size, but I didn't want to make them shorter than regular cards because I've had people give me cards like that before and it's irrtating. The smaller cards end up sinking down into the pocket of your wallet and you can't find them. They also don't stack very well with other cards. I figured printing cards that were half the size of a regular card (width-size) would do the trick. They basically turned out having similar dimensions to a stick of gum.
Initially I tried to order them from Moo.com, but I quickly realized they wouldn't show up in time before the conference, so I ended up printing them at home instead of sending them off to a print shop. I'm very happy with how they turned out:
Here's how I did it:
From there it was simple, I just exported my designs as high-res JPEGs and re-imported them into the business card software. I printed doubles of everything and then sliced them up using the x-acto knife.
Screenshots from Business Card Designer Plus:
Update: Thanks to Alix for re-creating the little guy from my business cards out of clay. These are freakin awesome, they even have the same retarded bug-eyes as mine :)