The math is straightforward but easy to get wrong manually under deadline pressure:
- Total document = trim + (2 × bleed) on each axis. A 85×55 mm business card with 3 mm bleed becomes a 91×61 mm document.
- Trim line matches the input trim size — that's where the cutter hits.
- Safe zone = trim − (2 × safe-zone-margin). Critical content inside this is guaranteed clear of the cut.
- Pixel dimensions at 300 DPI = total document × (DPI / 25.4) for mm. For inches, total document × DPI. The pixel count is what your editor's "image size" or "document size" dialog wants when you create a new file from a bitmap.
For commercial print, 300 DPI is the default. For large format (banners, posters viewed from a distance), 100–150 DPI is often acceptable. For close-up consumer products (photo books, business cards), don't go below 300 DPI.