Ordering big heads might feel almost too easy—upload a photo, place an order, and a few days later a perfectly-trimmed cutout shows up at your door. But how are custom head cutouts actually made? Behind that simplicity is a detailed production process designed to make sure your cutout is eye-catching, durable, and exactly how you imagined it.

Here’s a step-by-step look at how custom Build a Head head cutouts are made, from the moment you upload your image to the moment it’s delivered—so you know exactly what to expect when ordering from BuildaHead.com.

1. Uploading Your Photo: The Foundation of a Great Custom Head Cutout

Every great cutout starts with a great image.

When you upload a photo to BuildaHead.com, our system checks for basic requirements like file type and resolution. The best photos typically:

• Are well-lit (natural light works best)
• Are in-focus, not blurry or pixelated
• Show the full face with minimal shadows
• Have some separation between the subject and the background

Pro tip: A smartphone photo taken in good lighting is often better than a heavily filtered or compressed image. Screenshots are rarely a good option.

2. Image Review & Manual Cropping for Custom Cutouts

Once your order is placed, your image is reviewed by a real human—not automated software alone.

Our production team:

• Carefully removes the background
• Traces the outline of the head (or full body, depending on the product)
• Refines hair edges, hats, glasses, and facial contours

This manual cropping step is critical. Clean edges are what make a custom cutout look professional instead of homemade.

3. Proofing & Print Preparation for Large-Format Cutouts

After cropping, your image is prepared for print. This includes:

• Scaling the image to the exact size you ordered
• Color correction for accurate skin tones
• Adjusting contrast and sharpness for large-format printing

Large prints behave differently than photos on a screen, so files are optimized to ensure your cutout looks crisp from both up-close and across the room.

4. High-Quality Large-Format Printing for Head Cutouts

Your cutout is printed using professional-grade, large-format printers.

Depending on your selection, we print on:

• Foam-core (rigid, lightweight, premium finish)
• Cardstock (cost-effective and event-friendly)

We use fade-resistant inks to ensure vibrant colors and long-lasting results—especially important for events, photos, and displays.

5. Precision Cutting Your Custom Head Cutout

Once printed, your cutout is cut to shape using precision cutting equipment.

This step:

• Follows the exact contour created during manual cropping
• Produces smooth, clean edges
• Ensures consistency across multiple cutouts in the same order

For larger standups, this is where your cutout truly comes to life.

6. Stand & Structural Assembly for Life-Size Cutouts

If your order includes a stand, easel, or support, it’s cut out of cardboard at this stage of production.

This ensures your cutout:

• Stands upright on its own
• Maintains balance and stability
• Can be easily set up and moved

Our goal is zero frustration—no tools, no complicated assembly.

7. Quality Control Check Before Shipping

Before anything ships, each cutout goes through a final quality check.

We inspect for:

• Print clarity and color accuracy
• Clean edges and cuts
• Proper sizing and alignment
• Structural integrity

If something doesn’t meet our standards, it doesn’t ship.

8. Protective Packaging for Safe Delivery

Custom cutouts are carefully packaged to arrive safely.

Packaging is designed to:

• Prevent bending or warping
• Protect edges and corners
• Keep the surface clean during transit

Larger cutouts are boxed flat whenever possible to preserve their shape.

9. Shipping & Delivery of Your Custom Head Cutout

Once packed, your cutout is shipped directly to your door.

Most customers receive their orders within just a few business days, depending on shipping method and location. When your order arrives, setup takes seconds—just unbox and enjoy.

Why the Custom Head Cutout Production Process Matters

Every step in this process exists for one reason: to make sure your custom head cutout looks amazing in real life—not just on a screen.

From parties and weddings to trade shows and retail displays, a well-made cutout grabs attention, sparks conversation, and creates photo-worthy moments.

Frequently Asked Questions About Our Custom Head Cutouts

How long does it take to make a Big Head cutout?

Most Big Head cutouts are produced within 1 business day after you place your order unless you purchase a premium add-on (like touch-up or digital proof) which adds time. Shipping time depends on the delivery method you select at checkout, but many customers receive their cutouts within just a few business days.

What kind of photo works best for a custom head cutout?

The best photos are high-resolution, well-lit, and in-focus. A clear smartphone photo taken in natural light works great. Avoid heavy filters, low-resolution images, group photos, or images with shadows covering the face.

How big are custom head cutouts?

Custom head cutouts are available in multiple sizes, from handheld sizes to oversized and life-size options. Our Big Head cutouts on cardstock have a maximum size of 18x12 inches, while our Huge Head cutouts printed on foam-code start at 2 feet tall. The final size depends on the product you choose, the dimensions selected during ordering, and your image’s unique height-width ratio.

Are custom head cutouts made from cardstock or foam-core?

BuildaHead.com offers both cardstock and foam-core cutouts. Cardstock is lightweight and cost-effective for short-term events, while foam-core provides a more rigid, premium look that lasts longer and stands up better over time.

Can I use a custom head cutout outdoors?

Custom head cutouts are designed primarily for indoor use. Short-term outdoor use may be possible in calm, dry conditions, but exposure to wind or moisture can reduce durability.

Will my standup stand up on its own?

Yes. Our standups include an attachable easel or stand, allowing them to stand upright on flat surfaces without any tools or additional setup.

What happens if my image isn’t good enough?

If your photo doesn’t meet quality requirements, our team may reach out with recommendations or request a replacement image to ensure your custom head cutout looks its best.

Ready to Order a Custom Head Cutout?

Uploading a photo is just the beginning—but what happens after makes all the difference.

Create your custom head cutout today at BuildaHead.com and see the process turn your photo into a standout display.

Want help choosing the right photo or material? Check out our other guides or reach out to our team—we’re happy to help.