Industry Trends

FedEx Office Printing FAQ: What You Actually Need to Know Before You Order

Look, I’ve been handling print orders for marketing and corporate events for about seven years now. I’ve personally made (and documented) more mistakes than I care to admit, totaling roughly $3,500 in wasted budget on things like misprinted business cards and unusable posters. Now I maintain our team’s pre-flight checklist. Here are the real questions I get asked, and the answers I wish I’d had.

1. “What’s the biggest file setup mistake people make?”

Not checking the DPI at the final print size. Here’s the thing: your logo might look crisp on your screen, but that doesn’t mean it’s print-ready. The industry standard for commercial printing like business cards or brochures is 300 DPI at the final size. If you’re blowing up an image for a poster, you can sometimes get away with 150 DPI if it’s viewed from a distance. But for anything held in hand, stick to 300.

In my first year (2018), I sent a 72 DPI logo for 500 business cards. They came back fuzzy. $180 and a week’s delay later, I learned that lesson the hard way. Now, our checklist item #1 is: Image size (inches) x 300 = required pixel dimensions. Simple.

2. “Is ‘same-day printing’ actually same-day for everything?”

Probably not. And that’s a crucial distinction. To be fair, FedEx Office is one of the few with a nationwide network of print centers that can turn things around fast. But “same-day” usually applies to standard documents, basic flyers, or simple business cards from an approved template. If you walk in at 4 PM with a complex, multi-page brochure file that needs proofing and special paper? That’s likely next-day.

I once needed 100 presentation folders “same day” for a conference. The conventional wisdom is to just show up. In practice, I found they didn’t have the specific pocket style in stock for immediate production. What finally helped was calling the specific center ahead of time—something I do for every rush job now.

3. “How do colors on screen match what gets printed?”

They often don’t. This is the most frustrating part of digital design for print: your vibrant RGB screen colors are translated to CMYK ink. Blues and purples can shift noticeably. For brand-critical colors, you need a Pantone (PMS) spot color, which uses pre-mixed ink.

According to Pantone Color Matching System guidelines, a Delta E difference of more than 2 is noticeable to a trained eye. We once printed 1,000 event flyers where the corporate blue came out dull and grayish. The result? $450 wasted plus some embarrassment. The lesson: Always request a physical proof for color-critical jobs. It might add a day, but it saves money and reputation.

4. “What’s the real deal with paper weights? 80lb text vs. 80lb cover?”

This one confused me for ages. Paper weight is measured in pounds (lb) for text and cover stock, but they’re different scales. An 80 lb text sheet is much thinner than an 80 lb cover sheet. A good rule of thumb: business cards are usually on 80 lb or 100 lb cover (which feels thick and sturdy), while brochure interiors are often 80 lb or 100 lb text.

Seeing a flimsy business card vs. a proper one side-by-side made me realize why this matters. A cheap-feeling card undermines your brand instantly. For standard US business cards (3.5" x 2"), 80 lb cover (approx. 216 gsm) is the typical starting point for a professional feel.

5. “Can I really print and ship from the same place? How does that work?”

Yes, and this is a key advantage. You can have your items printed, then packaged and shipped via FedEx logistics from the same center. It’s integrated. But—and this is a big but—you need to account for the production time before the shipping time. Your 2-day shipping option starts when the package is handed to the driver, not when you place the print order.

After the third time we missed a client deadline by a day, I was ready to blame the vendor. The reality? We hadn’t built in the 48-hour print turnaround into our “2-day shipping” timeline. The checklist now has a simple formula: Production Days + Shipping Days = Total Lead Time. Done.

6. “What about online upload vs. going in-store? Which is better?”

It depends on the job’s complexity and your comfort level. For simple reorders of a file you know is correct, online is great. For anything new, complex, or where you have questions about materials, going in-store lets you feel paper samples and talk to a print specialist. That human interaction can prevent a lot of “I thought it would look like this…” issues.

I get why people love the convenience of online. But in my experience with 200+ orders, walking in for the first run of a new item has caught maybe a dozen potential errors. Things like, “Oh, you want this folded? That’s a different setup fee,” or “That font is going to be too thin to print clearly at that size.” Real talk: the five-minute conversation is worth it.

7. “Any hidden costs I should watch for?”

Design/template fees, proof changes, special finishes (like gloss coating on just one side), and bleed setup. “Bleed” is extra image area that gets trimmed off so color goes to the edge of the page. If your file doesn’t include it (usually an extra 0.125" on each side), they may charge to add it, or your final piece will have thin white borders.

In September 2022, we ordered 500 brochures. The file was “ready.” The final invoice had a $45 bleed setup charge and a $30 fee because we used a non-standard template. The mistake affected a $320 order, adding about 25% to the cost. Now, our final step before upload is to ask: “Are there any setup, proofing, or file-preparation fees for this exact configuration?”

8. “How do I make a large family tree poster or something custom like that?”

This is where their large-format printing comes in. You’d typically create the design in one piece at the size you want (e.g., 24" x 36"). Remember the DPI rule—150 DPI is often fine for a wall poster. Then, you’d upload it as a single file. They can print it on poster paper or even more durable materials like foam board.

The key is to ask about the substrate—the material it’s printed on—and the finishing. Does it need mounting? Lamination? Those services add cost and time. I want to say we paid around $120 for a mounted foam board sign a few years back, but don’t quote me on that. Prices as of January 2025; always verify current rates for your specific size and material.

Look, the fundamentals of good print haven’t changed: clear files, correct specs, and allowing enough time. But the ability to upload online, get quick turnarounds, and integrate shipping has transformed the execution. Just go in with your eyes open. Ask the questions. Get the proof. You’ll save money, time, and a whole lot of frustration.