When I first got into board game manufacturing, one of the challenges that stood out was designing token sheets for mass production. Tokens may seem like a minor component in a game, but they play a crucial role in both gameplay and production efficiency. Over the years at Hero Time, I’ve worked with countless game designers and publishers to fine-tune their token sheets, ensuring they’re high quality, cost-effective, and easy to manufacture. If you’re in the process of designing one, here’s what you should keep in mind.

Understanding the Purpose of a Token Sheet

A token sheet is essentially a large piece of thick cardboard with die-cut tokens that players punch out before using. These tokens serve various purposes—game pieces, currency, or markers—and their quality directly impacts the player experience.

From a manufacturing standpoint, a well-designed token sheet maximizes material usage while minimizing production costs. It’s a balance between making the tokens durable, aesthetically appealing, and easy to punch out while keeping waste low.

Choosing the Right Materials

One of the most important decisions in designing a token sheet is selecting the right material. At Hero Time, we primarily use greyboard (a recycled, compressed cardboard material) for its durability and eco-friendliness. It comes in various thicknesses, with the most common being 1.5mm and 2mm.

Thickness affects the feel of the tokens. A thinner token is easier to punch but might feel flimsy, while a thicker one provides a premium touch but can be harder to remove from the sheet. The goal is to find the right balance based on the game’s requirements. If your game involves frequent handling of tokens, opting for a thicker material with a reinforced coating can prevent wear and tear.

Designing for Cost Efficiency

Production costs are a significant factor in any board game. The more efficiently you use your token sheet, the lower your costs will be. A common mistake I’ve seen is designers leaving too much empty space on a token sheet. Since you’re paying for an entire sheet, it makes sense to utilize as much of it as possible.

One strategy is to design tokens that fit neatly together, reducing waste. Rounded edges also make it easier for die-cutting machines to punch out tokens without causing fraying. Another tip is to standardize the size of your tokens so they can be efficiently arranged on a single sheet without excess gaps.

Die-cutting costs also increase if the design has overly intricate shapes. While custom shapes can enhance gameplay and aesthetics, keeping cuts simple will reduce production time and costs. At Hero Time, we work closely with designers to optimize their layouts, ensuring maximum yield per sheet while keeping production smooth.

Best Practices for Design

A great token sheet isn’t just about fitting as many pieces as possible—it also needs to be user-friendly. Players should be able to punch out tokens without excessive force. If the connection points between the tokens and the sheet are too strong, players might accidentally damage them while removing them. On the other hand, if the connections are too weak, tokens might fall out prematurely, causing issues in packaging and transportation.

Another aspect to consider is the finishing. A matte or linen finish adds a premium feel, but it also increases costs. Glossy finishes are more resistant to wear but can make handling slippery. The choice should align with the overall aesthetic of the game and budget considerations.

Prototyping and Testing

Before finalizing a token sheet for mass production, I always recommend prototyping. At Hero Time, we create pre-production samples to test the durability, print quality, and punchability of tokens. This allows designers to make last-minute adjustments and ensures that the final product meets expectations.

We’ve seen cases where a seemingly perfect digital design doesn’t translate well into physical form. Maybe the punch-out connections are too thick, or the color saturation doesn’t appear as expected on the final material. These small but critical issues can be ironed out in the prototype stage, saving costly reprints and production delays later.

Final Thoughts

Designing a token sheet for mass production is a blend of art and science. It requires an understanding of materials, manufacturing constraints, and player usability. At Hero Time, we take pride in guiding game creators through this process, ensuring that their tokens not only look great but are also cost-effective and easy to produce.

If you’re working on a board game and need help with manufacturing, we’re here to make the process easy, right, and affordable. Feel free to reach out to our team, and we’ll help bring your vision to life.