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Print Production Essentials: Embossing, Foil Stamping, and Die Cutting

Print Production Essentials: Embossing, Foil Stamping, and Die Cutting

with Claudia McCue

 


Adding a die cut or emboss to your print job can make a striking visual impact; it's a way of sculpturing and increasing a reader's engagement with your work. Learn about the various types of embossing and die cutting as well as the proper ways to set up your documents to achieve consistent results. Author Claudia McCue covers manufacturing concerns like cost, time, choosing the appropriate paper stock, and file formatting; preparing your artwork for embossing and stamping; and then designing your die-cut project in Adobe Illustrator or InDesign.
Topics include:
  • Understanding how dies are created: hand-engraved, machined, or photo-engraved
  • Preparing files for die-cutting
  • Choosing appropriate stock
  • Creating artwork for single- or multi-level embossing
  • Checking proofs
  • Examining a cutting die
  • Handling a complex bleed

show more

author
Claudia McCue
subject
Design, Print Production, Design Skills
software
Illustrator CS6, InDesign CS6
level
Intermediate
duration
1h 28m
released
Jul 02, 2013

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Introduction
Embossing and die cutting: Paper sculpture
00:01 (MUSIC). Hi, I'm Claudia McCue.
00:06 During this course I'm going to introduce you to three ways to lure the reader.
00:10 What I call shape, surface, and shine. Die cutting allows you to shape your
00:15 printed piece. Takes it beyond the boring old rectangular format.
00:19 Embossing sculpts the surface of your paper.
00:22 It provides the double enticement of dimension and tactile engagement.
00:27 And foil stamping creates the shine that can turn paper into gold.
00:31 Of course all these processes require planning, and close collaboration with
00:35 your printer, even more so than a standard print job.
00:39 But these enhancements have the power to grab the attention of a reader.
00:43 To draw them in, and give your printed piece a chance to deliver its message.
00:48 So let's explore the visual impact you can add to your print projects, by using die
00:51 cutting, embossing, and foil stamping.
00:55
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What you should know before watching this course
00:01 During this course, I'll be showing you some techniques for creating artwork, for
00:04 embossing and die cutting, using Illustrator and InDesign.
00:08 So to make the most of those exercises, you should already be reasonably
00:11 comfortable in those programs. Certainly, you'll find lots of great
00:15 essential training courses here on lynda.com, to help you enhance your skills
00:19 in those applications. And in addition, if you'd like to know
00:23 more about print production in general, you might enjoy my print production
00:26 fundamentals course and the print production essentials, spot colors and
00:29 varnish course
00:32
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Using the exercise files
00:01 If you're a premium member of lynda.com library, you have access to the exercise
00:04 files used in this course. You can download this files from the
00:09 Exercise Files tab on the main page for this course.
00:12 For the movies in this course that have exercise files, you can load up the files
00:15 and then you can follow along with the same project that I'm working on.
00:19 If you don't have access to the exercise files, of course you can use your own files.
00:24 Okay, let's get started.
00:25
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1. Embossing Basics
The visual impact of embossing
00:01 There's no denying that embossing has a visual impact.
00:04 Of course it adds depth, here's a nice little piece.
00:08 It's just blind embossing. There's no printing, there's no ink on the paper.
00:12 The only thing that's carrying this art is just that depth of embossing.
00:16 There's a little bit of texture to the paper and the embossed area is just a
00:19 little bit smoother than the area around it.
00:23 That contrast of texture and height, makes a wonderful but subtle effect.
00:28 And embossing is tactile, it's sculpture. It's something that you can feel.
00:31 This is a lovely little piece. It's a promotional for Gutenberg's.
00:35 That's a company in the Atlanta area that specializes in creating embossing dyes,
00:39 and doing embossing and foil stamping. And so, they showcased their capabilities
00:45 here by using a multilevel emboss. You can see that the G is not quite as
00:48 pronounced as their company name Gutenberg's.
00:51 And then of course they've added some foil stamping.
00:54 And then that little bit of die cutting on the lower right, that little rounded corner.
00:57 Every little touch makes it something out of the ordinary.
01:01 And a piece like this just instantly conveys value.
01:04 This is a rich chocolate brown stock. It's beautiful paper.
01:08 And the embossed G, because of the pressure and the heat involved in the embossing.
01:13 There's just a little bit of scorching around the edges.
01:15 That sounds like a bad thing, but it isn't.
01:17 It really colors the edge of that G, just very subtly.
01:21 And it's almost sort of a polish. And that's something you can use to your advantage.
01:25 Scorching sounds like a bad thing but when you know what it's going to do, you can
01:28 actually use it as a component of your design.
01:31 A piece like this makes a lasting impression.
01:34 This is a promotional piece for Ink Systems Incorporated and they make ink.
01:38 I know you're not surprised at that. But you don't even have to read the logo.
01:42 The minute you see it, you know they have something to do with ink.
01:45 And you can almost feel that splat of ink. And it's a really, really nice looking piece.
01:50 And then a piece like this, that uses a multi-level embossing die.
01:54 And this is something called a combination die.
01:57 And that means that the embossing and the foil stamping happen simultaneously.
02:01 This looks a piece of metal. It looks like carved metal sitting on top
02:05 of the paper. You can image there was a lot of work
02:08 involved in creating this, but it's a really striking piece and it's a showcase
02:11 for the company that made it. So, keep these things in mind.
02:16 Embossing is really like paper sculpture and it adds depth.
02:20 And it adds life to a piece that you work on.
02:22 It takes planning, but the outcome is absolutely gorgeous.
02:25
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Die components
00:01 If you're working on a project that uses embossing, where do those dies come from,
00:04 and how are they created? Well, the first thing to consider is
00:08 something called the profile of the die. Now, keep in mind that a die consists of
00:13 the die itself, and then the counter. Now, all of the profile illustrations that
00:18 you're seeing are for embossing. Meaning that the embossed area's going to
00:22 push up above the paper. There's also something called debossing,
00:25 where that shape gets pushed into the paper.
00:28 Although, that's not used very often, the only difference would be essentially you
00:31 would turn this little set of pieces upside down.
00:35 But for all of these illustrations, they're meant to show a die that's
00:38 going to give you raised content on the page.
00:41 So, for what's called a single-level die, it's just going to push it all up one level.
00:45 So everything is going to be on one plain that's pushed up out of the paper.
00:50 That doesn't mean it's just going to be a big circle or a big square.
00:53 It just means everything's going to be uniform.
00:55 So you'd use a die like that for borders or rules or, or line art.
01:00 And you can see the shoulder of this shape is square, so it's sharp edges.
01:04 Could that be an issue? If you're trying to make a deep emboss in
01:08 some stocks you're going to find that they may be prone to tearing.
01:12 So there's always that sort of juggling act between the shape that you want the
01:16 embossing to accomplish And the behavior of the stock.
01:20 But then the people who create the dies can also help you judge how you're
01:23 going to create your artwork for the die. And what the limitations of the embossing
01:27 process are going to be. The multi-level die, as you can see.
01:31 And you're just looking at it in cross-section.
01:33 Can push the stock up to different levels. So not everything's going up to the same height.
01:38 So this gives you an opportunity to add little more visual interest, a little more
01:42 if you want to call it, a scultptural quality to it.
01:46 Round edge dies give sort of a soft transition from the base up through the
01:50 embossed area. And that can be a good way to handle stock
01:54 that's prone to tearing because it's sort of a gentle transition from The unembossed
01:57 area to the embossed area. And here's another solution to that
02:02 problem beveled edges. That has a more crisp edge than the round
02:06 edge die does, but it's good for heavy stocks because it's that transition that
02:10 little shoulder that pushes it up so it doesn't have a sudden move like the single
02:14 die that you saw earlier. So that may be helpful again with stock
02:20 that's prone to tearing. But for the really elaborate design,
02:24 sculptured dies. Now those are often, hand created.
02:28 They might be started with some machining, but they're going to be finished with hand creation.
02:32 Essentially they're engravings, they're carvings.
02:35 An you can do some beautiful things, especially with blind embossing.
02:38 An this is when you're really sculpting paper.
02:41 An you're capable of extensive details. So trees, an fur, an fine letters, an
02:45 things like that. Because of the work involved, you might
02:49 expect they can be significantly more expensive than other kinds of dies.
02:53 So what are dies made out of? Predominantly they're made out of three
02:58 metals, magnesium, it's good for single-level dies, it's a soft metal.
03:03 It's easy to mill, most of the time you're going to find that it's created with
03:06 what's called a photoresist and acid-etching.
03:09 It's essentially a photographic process where a chemical is placed on the metal
03:14 that is sensitive to light. And its exposed developed, and then where
03:19 it remains behind protects the metal. And then where the acid hits it, it's
03:23 going to etch away the metal and make, you know, little openings in the metal.
03:27 And it's going to leave that original surface, and that's going to be the top of
03:30 the die. One of the issues with magnesium is that,
03:34 well because it's soft, it may expand slightly when heated.
03:37 And what does this mean to your design? Well, it might mean that if you want to
03:41 register embossing with a printed sheet, magnesium might present a problem, it's
03:45 good for 15 to 20,000 impressions. The production time is usually one to
03:50 three days, of course that's going to depend on what other jobs are in the die
03:54 cutting company at the time, as you might expect.
03:58 Copper is a little bit harder than the magnesium.
04:00 It's good for single-level dies as well and it can be created the same way using a
04:04 photo-resist and acid-etching. Because it's a little bit harder than
04:09 magnesium, it doesn't expand as much as magnesium.
04:12 It's good for jobs that require tighter registers.
04:15 So if you did want to emboss a preprinted piece, you have a better chance of having
04:18 that embossed shape line up with artwork on the printed piece because it's harder.
04:24 It's also capable of longer runs up to a hundred thousand, and it's also a little
04:27 bit more expensive than magnesium diesyes. And the production time might be a little
04:33 bit longer than what you'd experience with the magnesium dies.
04:37 And then brass good for single level or multilevel, you've seen that its good for
04:41 sculptured dies. It can hold very fine detail.
04:45 Its hand-etched. Consequently, it's more expensive but it's
04:49 very well-behaved. Very little expansion under heat so you
04:52 have excellent register, so you can do fine detail.
04:56 You can line up with previously printed paper and be sure that things are going to
05:00 turn out the way your expect. Because it's harder, you can expect to
05:04 have long runs. But, as with everything that's better
05:07 than, you know, the other options, you can expect that your production time is
05:10 going to be longer. And it's going to be longer still if
05:14 you're creating a very complex die that has a lot of detail in it.
05:18 Keep in mind, this is very much like old-time engraving, there's a lot of hand
05:21 work and this sort of die is created by craftsmen who understand how die behave on paper.
05:28 But when you look at the possibilities, you have a wide range of options from
05:31 fairly affordable to fairly expensive. But this covers the range of the sort of
05:36 artwork that you might want to emboss. Who's going to make this decision?
05:40 Well, this is going to happen as a result of conversations you're going to have with
05:43 your printer. And if you deal directly with a finishing
05:46 company, they can advise you as well. But all of this is conversation you should
05:51 have early in the game, because these decisions really have a huge impact on the
05:54 success of a job that involves embossing.
05:58
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How dies are created
00:00 Creating an embossing die is a complex process, and when you look at the
00:03 components here, you start to get an idea of that.
00:08 Now here we're actually looking at the finished piece, and the components that
00:11 created the embossed effect. But you'll understand when you see this
00:15 what goes into the process. What he's putting inside the book Is going
00:19 to push the paper up. That's the actually embossing die.
00:22 And this is the concave version of that. And that's called the counter.
00:27 You can see that it's hollow. So as that paper is compressed, using heat
00:31 and pressure, it's going to be sculpted by those two dies.
00:35 The one on the bottom part of the paper's going to to push it up.
00:38 It's going to be pushed into the hollow parts of the counter.
00:41 And then it's going to be sculpted because of that process.
00:44 And then they went one step farther, and then added a spot varnish on top of this.
00:49 So, the result is something that's very shiny, it's very tactile, it has a lot of
00:52 dimension to it and it's something that really draws the reader in, it grabs the
00:56 buyers eye. But look at it closely.
00:59 And get a sense of the artisanship that's involved in creating this.
01:03 It really is a piece of sculpture that's used to create this dimensional effect on
01:07 a printed piece.
01:09
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Cost and time considerations
00:00 When you start contemplating a project that's going to involve embossing, you
00:04 have to sort of look down the line at your final deadline.
00:08 And you have to keep in mind that the more complexity involved in your embossing is
00:12 going to result in higher cost and of course, it's going to extent the time
00:15 required to accomplish all this. If you're using simple, single-level dies,
00:21 those can be photo-etched, and you could anticipate maybe a one to three day
00:25 production for those. The cost is going to vary with the size of
00:30 the die that's going to be created and the complexity of the detail of the die.
00:35 And that production schedule again is going to depend on the job load at the die maker.
00:40 When you start considering multi-level dies or sculptural dies, or combination
00:44 dies, which perform both embossing and foil stamping simultaneously.
00:49 Those require brass. And that's more expensive.
00:52 But it can hold finer detail. It's harder, it's better for longer runs.
00:57 But it also requires handwork. And handwork is time consuming and it's expensive.
01:02 So you should anticipate at least a three to five day production cycle for a complex
01:06 die like this, and it could be even longer depending on the work load at the die maker.
01:11 The cost, again, is going to vary with the size and the complexity of the embossing die.
01:18 If you're going to be embossing printed work.
01:20 That printed sheet has to be dry before it can be embossed, so that adds to the lead
01:25 time right there, and if you require tight registration between the embossing and the
01:29 printed sheet, that's going to require brass dies.
01:34 They can hold that tight detail. They're going to cost a little bit more,
01:37 and they're going to take longer to prepare.
01:40 If there are any problems, that's going to require a reprint or it could require a
01:44 new die or it could be both. If there's a problem trying to get that
01:48 brass die to align with the printed piece, if you're asking too much of that
01:52 combination of die and print and stock, you may have to back up and rethink some
01:56 of the components. So this is why you want to plan far ahead.
02:01 You want to consult with the printer, consult with the die maker.
02:05 Make sure that your choice of stock is appropriate for what you trying to accomplish.
02:09 And make sure that you have a realistic notion of the deadlines involved and the
02:12 anticipation of the result. So, the job planning involves at least the printer.
02:18 And most printers don't create their own dies.
02:21 They certainly don't usually create complex dies.
02:24 So, then you're talking about job planning in both companies, the printer and the
02:28 finishing supplier. So as soon as possible, when you're
02:31 planning a job like this, try to get them both involved.
02:35 Because you can coordinate your schedules and they can educate you about things that
02:38 you might need to change as you prepare to send this job for production.
02:43 And keeping in mind that those schedules have to all be synchronized.
02:46 There's a lot to think about. And that's one reason there's no such
02:50 thing as too much time. A job involving embossing is not something
02:54 you want to rush.
02:55
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2. Manufacturing Considerations
Choosing appropriate stock
00:00 As you start planning a job that's going to use embossing, stock is a consideration.
00:05 You should consult your printer if that's who you're dealing with.
00:08 Or if you have a direct relationship with the die maker, talk to them.
00:12 If you think of it this way, paper and embossing is sort of a recipe, and you
00:15 want to be a good cook. The stock weight, of course, is important
00:19 as you might expect, heavier stock responds well to embossing.
00:23 But the die may have to be created deeper in order to provide definition for certain
00:27 artwork if it's very heavy stock. One of the things that happens with heavy
00:31 stock, is that, even though it will hold shape well.
00:34 It can also try to collapse. It tries to go back to its former shape.
00:38 So it may have to be pushed deeper than what the finished emboss level ought to be.
00:43 The surface or the texture of the stock is important.
00:45 You'll find that felt finishes are the best for maintaining detail.
00:49 If the stock has very pronounced texture, it could complete with small details in
00:53 your embossing art. Although the contrast between textured
00:56 stock and the slight smoothing that happens during embossing can actually be
01:00 kind of interesting. Long fiber stock works better than short
01:04 fiber stock for deeper embossing because it stretches better and still holds together.
01:10 Stock grain is important, too. If you have artwork with, let's say,
01:14 horizontal components and you're aligning those horizontal components with a
01:17 horizontal grain in the paper. That could cause cracking, so you might
01:22 consider changing your artwork, or perhaps changing the angle that you're embossing.
01:27 As much as we want to be sustainable, as much as we want to recycle, you may find
01:31 that recycled stocks can be inconsistent under embossing, and that's because
01:35 they're created out of a combination of original fiber.
01:40 So it's a good idea if you use stock that is composed of less than 30% post-consumer waste.
01:47 If you're using coated stock or varnished stock, or stock that's already printed,
01:51 you have to keep in mind that paper stretches but coatings don't.
01:56 And so coatings may crack or split. Especially with deeper embossing.
02:00 And often, there's heat applied during embossing, and with thin stocks that are
02:03 coated, they can become brittle. And that may not be obvious early on in
02:07 the job, but during the life of that printed piece, it may become a problem.
02:12 Now, shallow embossing may be okay with these stocks, because you're not pushing
02:15 the paper quite so far, and maybe you don't break the integrity of the coating.
02:20 Stock color can be used as sort of part of the artwork.
02:23 For instance, if you're using blind embossing on white stock, that makes for a
02:26 beautiful result. If you're embossing on darker stock, you
02:30 may find that your embossing needs to be deeper, so that you can see sufficient
02:33 contrast between the shape of the emboss and the color of the stock.
02:39 And if you're embossing stationery keep in mind that, that may be run through a laser printer.
02:44 And that means that it's going to be subjected to pressure and to heat.
02:48 So it might flatten the embossing back out.
02:50 So in anticipation of that, you might go for a more shallow emboss.
02:54 And that way, if it gets flattened a little bit, maybe it isn't so apparent.
02:59 But as always, have good conversations with your printer as early in the job as possible.
03:03 If you're dealing directly with the die maker, help them give you advice about how
03:07 to create your artwork and how to set your expectations for the success of the job.
03:12
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Embossing preprinted stock
00:01 You're frequently going to be combining embossing and printing.
00:05 Now, if you're performing blind embossing, which is embossing that takes place on
00:08 unprinted stock, that's not an issue. If you're performing blind embossing on an
00:13 unprinted area of printed stock, that's usually not a challenge unless it's too
00:17 close to the printed area. And then, there might be some buckling.
00:22 So that's something to take into consideration as you're designing.
00:25 But registration to a printed area, as you might expect, requires precision.
00:30 And that usually requires the creation of brass dye.
00:33 As for the embossing, they're more expensive, but they can hold finer detail,
00:36 and they're capable of longer runs as well.
00:40 Brass dies almost always require some hand work.
00:42 And that's time-consuming, and it's expensive.
00:45 And if there are errors, those can be really costly.
00:48 Because if you're embossing and you find out it's not what you want, if you find
00:51 out you just simply can't hold the detail that you want, or it's having awful
00:55 results on the printing. Then you're going to have to go all the
01:00 way back, reprint the job, recreate the dye, essentially you have to start over.
01:04 And this is why you want to test early on and you want to make sure that you
01:07 understand how everything's going to behave when it all falls into place.
01:12 You can do some really neat things with this.
01:14 This is a cute little bit of artwork, but the customer wanted to make it
01:17 dimensional, they wanted to emboss it. And they used a multilevel die, so you'll
01:22 notice that the circle comes up to one depth and then the horse is a little big
01:26 higher and then the stars are higher still.
01:30 So, it looks really nice on white heavy stock that's just got a little bit of
01:34 texture to it because the embossing smooths out the embossed area.
01:39 And then of course it raises it up and it gives it that sort of textural feel.
01:43 Here's what could happen, and this is an exaggeration, but if things went wrong.
01:47 If the dye wasn't registered correctly with the printed area, naturally this is
01:51 going to be unattractive. And this is what I'm talking about when I
01:55 say, if things go wrong, then you're going to have to reprint.
01:58 You can't re-emboss the sheet. You need a fresh unembossed sheet to start
02:01 over with. This is highly unlikely that things would
02:04 ever go quite this badly but it's something to keep in the back of your mind.
02:08 Maybe you're over complicating your job. Maybe you can get a nice effect but do it
02:11 with a little bit simpler approach. And you always have to keep in mind that
02:15 there's going to be some distortion when you emboss because really you're sculpting
02:18 the paper, you're stretching it. And if it's a really deep emboss, it may
02:23 distort the artwork, or it could distort adjacent printing.
02:27 So you want to have it in sort of an open area.
02:29 And of course larger details are easier to emboss than little, tiny ones.
02:34 And one of the things that's sort of unavoidable.
02:36 If you're embossing a printed piece, keep in mind that paper stretches, and coatings
02:40 and inks don't. If it's a very heavily printed piece, if
02:44 it's a dark piece, dark ink, heavy graphic coverage, you have to worry a little bit
02:48 about cracking, and what do you do to fight that.
02:53 Well perhaps you don't emboss as deeply as you originally planned.
02:56 And pieces with varnish you should avoid if you possibly can, trying to emboss a
03:00 piece that's varnished or coated in any way.
03:04 But any time you're considering using embossing, you want to consult with a
03:07 printer and if you're consulting separately with a die-maker, talk to them,
03:10 and start early on. Let them know what your plans are, and
03:14 they can help guide you so that you don't get yourself too far down the line in
03:17 production and then find out that things are not going to work the way you expect.
03:22 After all, you're going to all this extra effort, you want it to be a beautiful
03:25 piece when you're done.
03:26
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3. Preparing Artwork for Embossing
When to start working on a die: Early in the job
00:00 I'm sure you're not surprised to know that adding embossing to a job adds to the
00:04 complexity of the job. And it also adds to the complexity of
00:08 planning for the job. So, if you're entertaining the notion of
00:11 adding embossing to a project, when should you start the planning?
00:16 You know, right about now might be a good time.
00:18 Here are some questions to ask the printer or finisher.
00:21 And I put both terms there, because most often you're going to deal with the printer.
00:26 And if the printer doesn't perform his own embossing, he's going to pass that job off
00:29 to the finisher to do the embossing. Sometimes you'll deal directly with the
00:34 finishing company. So these questions still apply either way.
00:39 You want to determine early on what the appropriate stock is for a project.
00:44 And given that stock, how deep can the embossing be?
00:46 How deep should it be? Even though you're not going to create the
00:50 die, it may be helpful for you to know what kind of edge is best.
00:53 A beveled die? A rounded die?
00:56 Because that can have some impact on your design.
00:58 Especially how you handle text and small art components.
01:02 You need to know what the safe live area is.
01:04 In other words how far away from folds and trims should you stay as you plan deciding
01:08 where your embossed area is going to be. And to some extent, the press that the
01:14 job's going to print on and the embossing machine could have some determination of
01:18 those capabilities. Of course you need to know the press
01:22 schedule on any print job and you need to make sure that you submit your files in
01:25 time for that, but now you have a second schedule to consider, and that's the
01:28 finishing schedule. Again if you're dealing with a printer
01:33 directly they're going to try and keep you on track for both what they need and what
01:36 the finishing company needs. So, when is the die artwork due?
01:41 Well, that's something that's going to be determined by that schedule and you need
01:44 to make sure that they tell you if they have any special instructions for artwork.
01:49 In other words, how would they like for you to indicate the depth levels if you're
01:52 creating a multi-level die? And any specs for minimum size of type or
01:57 other art details. Oh, and one more thing, beat your deadlines.
02:02 If you do that, your printer and your finisher will love you.
02:06
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File Format and other considerations
00:01 Of course when you're working on any job for print, you should communicate with
00:03 your printer. But when you're working on a project that
00:06 involves embossing, you really need to be careful about the way you communicate with
00:09 your printer or your die maker. There are a lot of details that you need
00:13 to know when you're preparing your work for this kind of a job.
00:18 Early on, you should specify whether the embossing is going to be blind embossing,
00:21 and that means embossing on an area of the job that's not printed.
00:25 Or whether it's going to need to be registered to print, because that may
00:28 dictate the material that they use to create the die.
00:32 And that may also dictate the kind of artwork you can use in embossing.
00:36 And of course you should ask how art should be supplied for any embossing project.
00:41 But especially one that involves embossing and foil stamping on the same area.
00:45 That's something called a combination die. Always indicate the kind of edge that you
00:50 want on the embossing. Do you want it to be beveled?
00:53 Do you want it to be rounded? And you should ask the printer or the die
00:56 supplier to recommend the most appropriate kind of edge for the kind of art that
00:59 you're supplying, and also the kind of stock that you're going to be embossing.
01:04 You should supply your art at 100%. Ideally, you supply vector artwork, but if
01:09 you have to supply raster artwork, then make sure that it's high resolution.
01:13 It should be at least 600 pixels per inch and it should be a bitmap image, not a
01:17 greyscale image. The bitmap image is just black and white,
01:21 no shades of grey. Always ask what version of file the
01:24 printer or die maker prefers. Should it be a native Illustrator file?
01:28 Would they rather have an EPS? Do they want PDFs or PSDs?
01:32 And make sure you know which software version they want to use.
01:35 For example, if they're using an older version of Illustrator than you are, you
01:39 need to back save. When you're creating artwork in
01:43 Illustrator, don't use any masks. No screens, so you can't have any halftone patterns.
01:49 No compound paths. Try to avoid intersecting lines, and avoid
01:52 strokes, and other artwork components that are like strokes, that are finer than two points.
01:58 And it makes sense that you'd want to also avoid extremely small text, anything
02:02 smaller than 12 points. Or fonts with very, very fine serifs.
02:08 Convert your type to outlines, and as you're creating your type, allow a little
02:12 extra spacing between the lettering. Remember it's going to push that paper up
02:16 into the die. So you want to increase the spacing so
02:19 that you can have deeper embossing. And for beveled-edge embossing, the
02:23 artwork should be slightly fatter than the desired finished size.
02:27 Because, as that beveling happens, the embossing gives sort of an optical
02:30 illusion of shrinkage of art. So a rule might seem finer.
02:34 Or lettering might seem more narrow. So make it a little bit fatter in
02:38 anticipation of the embossing. Really fine details are going to look
02:42 better with a shallow emboss. If you're going to emboss large, bold
02:46 shapes, well, go for deeper embossing. When you're choosing the area of the
02:51 project that's going to be embossed, leave at least a half of an inch, or one inch or
02:54 more, between the embossed area and the adjacent folds or trims.
02:59 And that's because it might buckle if it's too close to a fold or a trim.
03:03 You should try to avoid embossing a sheet that's printed on both sides.
03:07 But if you just have to, remember to keep the text away from the embossed area on
03:10 the back side. Or it's going to possibly be warped and be unreadable.
03:15 Just remember, you have to prepare for print anyway, but when you're preparing
03:19 for something as complex as embossing, you should communicate with your printer and
03:22 the die maker as early in the project as possible.
03:26 And they can help you prepare your artwork so that you don't have disappointment
03:29 later in the project.
03:31
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Creating artwork for single-level embossing
00:01 We want to enhance this little card by adding some embossing.
00:04 Won't be very fancy. It will just be a little simple single
00:06 level dye. And because that's our approach, I'm going
00:09 to have to change a little bit about my art work.
00:12 And here's why. Here where I have these two balloons
00:15 overlapping, if they are embossed it's just going to make sort of a one blob with
00:18 two lobes to it. It really look like two balloons.
00:22 If we were going to create a multilevel embossing dye then we could emboss this
00:25 balloon, push it up a little bit and then we could emboss this balloon at higher
00:28 sculpture, you know, we push it in further into the paper, and that way we would see
00:32 some distinction between the two balloons. But we're not going to do that.
00:37 We just want to do something simple just to give it a little bit of visual
00:40 interest, but we really don't want to get involved with the expense involved with a
00:44 multilevel die. So, because of that,m I'm just going to
00:48 modify my design. So I'm going to move this balloon down so
00:51 that they are now two separate shapes and I also want to make sure that there's
00:54 enough room in between the balloons so that there'll be the embossing and then
00:57 the paper has room to flatten back out. Remember that what happens during emboss
01:03 is essentially the paper gets stretched and sculpted.
01:06 So with that in mind, I'm going to make sure that I have enough room between the
01:10 balloons so that that paper can sort of relax again.
01:13 And also that same consideration here. This is where somebody is going to write a message.
01:19 I want to make sure that the paper can flatten back out so that there is no
01:21 deformation where they're going to write. I think this balloon is okay.
01:25 And I also want to emboss this text. So again, I want to have enough room
01:28 between the balloon and text and I think we're okay here, and I have a bit of a
01:31 head start with the text because there's already plenty of room between the letters.
01:37 If the letters were much too close together, I'd have to move them apart, but
01:40 with the way they're set now, I think everything's going to be fine.
01:44 So my artwork's in position, but now I have to create artwork that's going to be
01:47 used to create that embossing die. So I'm just going to duplicate my little
01:52 balloon shapes and my text, and create a new layer and a new color, and that's
01:55 going to represent the embossing. So first, the new layer.
02:00 And of course, I'm just going to call it Emboss.
02:02 And now I'm going to create the color. So in my swatches panel I'm just going to
02:08 choose New Swatch and I'm going to name it Emboss, naturally.
02:12 It's going to be a spot color. The color itself honestly doesn't matter
02:17 it's really just representing an area. I tend to like to make those colors really
02:21 bright and obvious so it's clear that they aren't part of the art work but that that
02:24 they serve a different purpose. So I'm going to choose OK, and now I'm
02:29 going to duplicate the artwork so that I can then assign that color to the
02:31 duplicate artwork. So I'm going to select my balloons by
02:36 Shift clicking and I'm going to get my text as well and you can see this little
02:39 selector square here in the Layers panel. All I have to do to duplicate Illustrator
02:45 even tells me. Click to select.
02:47 I'm going to duplicate it and hold down Alt on Windows or Option on the Mac.
02:52 And that duplicates the artwork. So it still remains in its original
02:55 location but now I also have it in my top layer.
02:59 Of course we can't see it, because it's white.
03:01 But what I'm going to do so that I can keep track of what I'm doing, is I'm
03:03 going to turn off all the artwork in the underlying layer.
03:07 I still have that blue shape to help me keep going.
03:10 I'm not going to emboss the strings, I'm just going to emboss the little globes of
03:12 the balloons. So, I'm going to delete the strings from
03:15 my emboss layer, so I don't want them involved in my emboss artwork, so I'm
03:19 going to ungroup them with Object and Ungroup, and for the rest of them I'm just
03:22 going to use the keyboard shortcut, which is Command Shift g on the mac and Control
03:26 Shift g on Windows. This saves me a little bit of time.
03:32 And then, I'm just going to get rid of the strings.
03:36 Now we just have balloons, and then, of course my text.
03:40 Again, since my little blue shape is locked, I can actually just select all of
03:43 this at once. And then I am going to apply that fill
03:46 color which is my emboss. And there we go.
03:50 Now, here's something to keep in mind. I'm going to turn everything back on.
03:53 If we decide that we're going to move one of these balloons, or we're going to
03:56 resize it. Then we have to remember to do the same
03:59 thing to the emboss artwork. They are dependent on each other, so
04:03 always remember that whatever you do to your artwork, you have to do to the
04:06 emboss, and vice versa. So now this is ready to send off to the printer.
04:12 And then the printer is going to coordinate with the die-making company.
04:15 And they're going to create the embossing die.
04:17 And then when the job's printed, they'll send it over to the embossing company.
04:21 And they'll do the embossing. And I think this is going to look really
04:23 cute when it's done. It's not going to be very pronounced, but
04:26 it's just enough to give a little bit of shape and a little bit of visual interest.
04:30 So now that you've seen this happen. I think this gives you an idea that it's
04:33 really not that hard to do.
04:35
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Creating artwork for multilevel embossing
00:01 If you're working on a project that involves multi-level embossing, you should
00:04 first consult with your printer or die maker, and let them tell you how to
00:07 prepare your artwork properly so that you get the result that you have in mind.
00:12 We're working on a project for a client who's creating their annual report, and
00:15 they want to do something with their logo to make it look more interesting.
00:20 This is their logo and, rather than just printing it, they've decided that they
00:24 want to emboss it. And rather than using a simple single
00:28 level emboss, they want to do a multilevel emboss.
00:31 So they've provided us this comp that they created in Photoshop that gives us a rough
00:35 idea of what they have in mind. The three little arcs at the left are
00:40 going to emboss at different depths. The left arc just slightly.
00:44 The middle arc a little bit more and then the third arc is going to emboss the most deeply.
00:49 So this is something we could provide to our dye maker but we have to give them
00:52 artwork to use. So this is how our dye maker has asked us
00:56 to supply the art. It's going to be vector art supplied in
01:00 illustrator, and we've used spot colors to indicate the different levels of embossing.
01:05 The light orange is going to be the slight emboss.
01:07 The dark orange is going to be the more pronounced emboss and, then, the green is
01:11 going to be the deepest of all. The text, incorporated, is just going to
01:15 print in a metallic silver. And knowing where that falls in
01:19 relationship to the logo, helps the die maker know how to register the embossing
01:22 die to the printed sheet that they're going to emboss later.
01:27 And how are they going to use this art work?
01:28 They're going to use it to mill a brass die and each separate color is going to
01:32 enable them to mill to a different depth. And that's how the composite dye is going
01:37 to be created, and we think that kinetECO is going to really like the way their
01:40 annual report looks.
01:42
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Sculptured embossing
00:01 The most advanced form of multilevel embossing is something called sculptural embossing.
00:06 It really is paper sculpture. So that multilevel aspect adds dimension.
00:11 It requires brass dies so they can hold the detail.
00:15 And brass dies almost always require hand work anyway.
00:18 But when you're creating something that's really a sculpture.
00:21 That's going to require an artist's touch. It really is a form of engraving.
00:26 So how do you provide the artwork to the die maker?
00:28 Vector art as much as you can for sharp components.
00:32 And then separate the layers out for each level of embossing.
00:36 And it's really just sort of a crude start.
00:38 It gives them a start for milling when they create sort of the base of the brass sculpture.
00:44 And it's going to be up to the die maker to do some engraving, and hand work to
00:47 refine it. It's helpful if you provide a Photoshop
00:51 file or a sketch that indicates how you want the shading to be handled.
00:56 So this is really just a start for the die maker.
00:59 It's going to show them the size. And where the lettering's going to go and
01:02 so forth. And they'll use this as a starting point
01:05 for milling out that piece of brass. This gives them a general idea of how we
01:11 want the edge of that milled die to be. How we want the lettering handled, how we
01:16 want that rim around the outside handled and, of course, the text.
01:21 But the head is going to have to largely be handled by hand.
01:24 What happens when they mill, they're just going to sort of leave a general area
01:27 there for the head. And then it's going to be up to the die
01:30 maker to refine it. Here's the little sketch to give them a
01:34 rough idea how we want it shaded. But again, keep in mind the die maker
01:38 really is a sculptor, and you have to rely on his instinct to do the best job.
01:44 When this piece is finished, it's been embossed with something called a
01:47 combination die. And a combination die performs embossing
01:51 and foil stamping simultaneously. It looks like a piece of metal coming out
01:56 of the paper. It's an absolutely gorgeous piece.
01:59 And the dye maker did a fabulous job on it.
02:02 We just gave him a start, he's the one who really made it shine.
02:05 This is truly craftsmanship in printing. It's created by artisans, it requires an
02:09 artist's touch. That dye is one of a kind.
02:13 The dye itself, honestly is a work of art. But it's a collaboration between you as a
02:17 designer and the die maker, and you should think of him as a sculptor.
02:21 And it's really something to be proud of when the job is finished.
02:24
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Checking an embossing proof
00:00 Before an embossing job goes into full production, usually the die maker will
00:03 provide you with what's called a strike. It's a proof.
00:08 It's a test emboss of the stock that's going to be used on the final job.
00:13 And you need to inspect that to make sure it looks the way you expect.
00:17 You want to check the depth; is the embossing the proper depth you were expecting?
00:21 And if you're using a multi level or a sculptural embossing die, make sure
00:24 there's sufficient difference between the levels, and you can see the detail that
00:27 you were hoping to capture in the embossing.
00:30 And, speaking of detail, you want to check for broken type, broken rules, any small
00:35 art components. You want to make sure that they're
00:38 rendered with fidelity. You want to check for distortion.
00:42 Are smaller details distinct? And since embossing involves pressure, and
00:46 you're really just sculpting the paper, you want to check for stock buckling.
00:50 And this is especially true of very heavy stock.
00:54 And if you're performing the embossing near a trim or a fold, you want to stay a
00:57 certain distance away from trims or folds. But in heavy stock, it can still have a
01:02 bit of deformation of the stock. Because heat is often used during
01:07 embossing, you might see some scorching of the paper.
01:10 Not so much with dark stock but with light stock, you might see a bit of scorching.
01:14 You can actually use that sort of as an artistic component.
01:17 A lot of people do. But if it's not what you want, then you
01:20 may have to either change the stock or you might have to change a bit about the dye,
01:23 so that not so much heat is required and that no scorching occurs.
01:29 If it's thin paper or if it's coated paper you have to beware of tearing.
01:33 If you're embossing printed pieces. then you have to check for registration.
01:38 So does that embossed area align with the printed area?
01:41 If you're using a combination die you want to make sure that the foil aligns
01:44 with the embossed area that it's supposed to align with.
01:48 And you want to make sure that it interacts with that foil correctly.
01:51 You want to check for splitting or tearing.
01:53 So just like going to a press check for a job that purely invovles print, this
01:57 really counts. When you're looking at a press proof or
02:00 you're looking at a proof that a printer gives you before running a press job.
02:05 This is the time to really pay attention to all the details because once you set it
02:08 in motion, you want to make sure that your going to be happy with the finished piece.
02:12 You put allot of work into a job that involves specialty finishing like
02:15 embossing and you really want it to turn out nicely.
02:18
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4. Foil Stamping
Examples of foil stamping
00:01 Before we start talking about the mechanics of foil stamping I think it
00:04 might be inspirational to see some great examples of foil stamping in use.
00:09 Now when you hear foil you think metallic and a lot of foil stamping is metallic
00:13 foil stamping and this is a beautiful piece that has some metallic foil on it.
00:19 And it also has die-cutting and embossing. This is pretty much every wonderful thing
00:23 you could do to a piece of paper except put ink on it.
00:26 If you look at that script G in the background, you might think that's black
00:30 ink, but it isn't. It's actually a clear foil.
00:33 And it's a little hard to show you here. But all it does is put shine in that area.
00:38 It's similar to the effect that you would get with a spot varnish.
00:41 But it's a much higher shine, it's a beautiful piece showcasing all the things
00:44 that these guys know how to do with foil stamping, and embossing, and die cutting.
00:50 And here's another example of clear foil. Here it's being used in combination with a
00:54 blind emboss. And it adds just a little bit of color to
00:58 the paper. It adds a pearlescent look so it's very
01:01 slightly opaque and it makes the ampersand a little bit lighter that the paper around it.
01:06 But, it's also a bit pearlescent and it's a very subtle effect that's really
01:09 beautiful overall. And this piece is using two combination dyes.
01:16 Now combination dye performs both embossing and foil stamping simultaneously.
01:22 So there's one combination die that performs the embossing and applies the
01:25 gold foil and another combination die for the embossing and the blue foil.
01:31 And you can imagine the precision and the planning involved in creating a piece like this.
01:35 But it really is a work of art when it's finished.
01:39 So when you see these, let that inspire you.
01:41 Let that make you think of what you can do that goes beyond just ink on paper.
01:45
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The basics of foil stamping
00:01 There's more than one way to add shine to your printed project.
00:04 One method is called cold foil. Now, cold foiling happens on press.
00:09 An adhesive is applied to the paper, much like ink would be, and then the foil is
00:13 adhered to that adhesive area and then it's cured with UV light.
00:18 One of the beauties of cold foiling is that it can hold very fine details like
00:21 small type or thin art components, even halftones.
00:26 And it's capable of large area coverage. You can over print it, which means that
00:30 your range of color is pretty much unlimited.
00:33 So you can apply process colors you can even use pan tone colors on top of that
00:36 cold foil. Because it happens on press, registration
00:40 is not an issue. And you don't have to create any dyes for
00:44 cold foils. So that means that you don't have that
00:47 wait time for a dye to be created. There's no change to the stock texture,
00:51 because there's no pressure used to apply cold foil.
00:54 And that also means that there's no stock deformation.
00:57 You don't have the warping that you might have with.
01:00 Application of hot foil, that means that you can put cold foil closer to a fold or
01:03 to the edge of a sheet and you don't have to worry about sustainability.
01:09 Cold foil is easily recycled, it uses standard techniques, it doesn't require
01:12 any kind of special handling. Now cold foil isn't quite as highly
01:17 reflective as hot foil. It's getting closer all the time.
01:21 You can't apply it as part of embossing, but you can emboss it afterwards, so you
01:25 can apply the cold foil on press and then perform that embossing afterward.
01:30 For maximum metallic look, you want to use hot foil.
01:34 You have a wide range of color choices, very high reflective.
01:39 Now, when you hear foil, you naturally think metallic.
01:42 But there are other kinds of foils as well, that aren't metallic.
01:46 Why would you want to use that? And they come in both gloss and matte.
01:50 If you've ever tried to print white type on black stock, you know what a challenge
01:53 that can be. Printing ink is not opaque.
01:57 And so that means that you have to apply two passes of ink.
02:00 And even then, it's not really going to completely cover that dark stock.
02:04 But foils can do that. Foils are opaque, so if you want to print
02:07 white or other light colors on top of dark stock, you might find that foil is really
02:11 a better answer than printing ink. And then there are clear foils.
02:16 Now, why would you use a clear foil instead of what seems to be the same
02:19 effect, a spot varnish? Well there are some neat effects that you
02:23 can do with foil that you can't quite do with varnish.
02:25 For example, sort of pearlize looks and iridescent looks that are possible with foils.
02:30 And then of course there are the holographic and diffraction foils.
02:33 They look like metal but then they have these rainbow effects.
02:37 Very, very attractive, really catches the eye.
02:40 Some things to think about when you're considering using hot foil.
02:44 It can be applied over or under inks, you can use it in a piece that's going to be
02:47 laminated, you can use it in a piece that has varnish involved and, of course, you
02:51 can combine hot foil with embossing and this is sort of counterintuitive some
02:54 times hot foil is actually less expensive than metallic ink.
03:00 And keep in mind that if you've used metallic ink, you know that it doesn't
03:03 really look like metal, but hot foil can really look like metal.
03:07 But you also have to keep in mind that there's some lead time involved because a
03:11 die has to be created in order to apply hot foil.
03:14 It's applied offline. It's not something that happens on press,
03:17 and you have to make some considerations when it comes to stock choice.
03:22 Smoother stock, as I think you would expect, gives you a shiner, more
03:25 reflective result. If you're using textured stock, the heat
03:28 and the pressure that's used to apply hot foil, is going to subdue that stock
03:32 texture, so you're going to see some flattening.
03:35 That can actually be kind of neat, you can see that contrast between the texture of
03:39 the stock and the smooth area of the hot foil.
03:42 And you can actually use that to your advantage.
03:45 You want to make sure that you're using the appropriate formulation of foil for
03:48 the stock, but that's not really something you have to worry about that's a result of
03:51 the collaboration between your printer and the company that's going to be actually
03:55 doing the foil stamping. You don't have to worry about
03:59 sustainability or recycling, there's no special handling that's required for
04:03 dealing with a piece that has hot foil as part of the printing.
04:07 There's an interesting process called UV casting.
04:11 What happens is that a mold is made with little tiny grooves in it and then a UV
04:15 varnish is applied on press and that mold is sort of pressed into it.
04:21 This happens on press in very similar to applying a spot varnish or any other kind
04:25 of coating. But then there's a diffraction effect that
04:29 appears on top of that area. It's just like a UV ink.
04:33 It gets a UV cure. It can be combined with cold foil,
04:35 although usually that doesn't happen on the same pass.
04:38 Now, it's not as brilliant as diffraction foils.
04:41 But the fact that you can apply it inline on press is kind of a plus.
04:45 An you can put it on top of ink, or cold foil, or hot foil.
04:50 Now of course we're talking about, foil stamping and things that happen on top of
04:53 a printed piece. But you might want to keep this in the
04:56 back of your mind. There are also substrates that give you shine.
05:00 one kind is something called transfer metallized substrates.
05:04 If you want to get technical, what happens is that aluminum is vaporized an then it's
05:07 vacuum deposited onto a carrier. That carriers glued to the substrate and cured.
05:13 And then that carrier film is removed. And it just leaves the metal behind.
05:17 In a way, it's sort of like you've plated that piece of paper.
05:20 And it comes in gold and silver, and some defraction and holographic finishes.
05:25 One of the beauties of this approach is that it does not delaminate.
05:28 It really does become part of that paper surface.
05:32 You have to keep in mind that if you're going to print light colors, like skin
05:35 tones or pastel tones. You're going to have to print opaque white
05:39 ink before you print those colors. It's sustainable, it's easily recycled.
05:43 Again, it doesn't require any kind of special handling.
05:47 Another approach is something called foil laminate substrates.
05:50 And in this process, metallized film is laminated to the paper substrate.
05:56 Good ink adhesion. You can overprint any ink on top of that.
06:00 Process inks or spot inks. Very striking visual impact.
06:04 And on top of that shiny substrate, you can emboss and foil stamp.
06:08 So you can really get carried away. Again, because you're printing on that
06:12 sort of metallic looking substrate, if you're going to print pastels or skin
06:15 tones, you'll have to print an opaque white ink first.
06:19 Now, this is something you have to plan ahead.
06:22 You have to obtain that stock ahead of time.
06:24 It's not something that's usually in stock at a printing company.
06:28 But again, don't worry, it's sustainable, easily recycled Doesn't require any kind
06:31 of special handling. So when you think about all this, you can
06:35 see that you have a wide variety of choices when it comes to adding some shine
06:38 to your printed piece. You can even combine them for additional impact.
06:43 I think the hard part is going to be making up you mind what you want to use.
06:47
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Design considerations for foil stamping
00:00 When you're planning and designing artwork for a job that involves foil stamping,
00:04 there are some considerations. When you're using hot foil, it's important
00:08 to choose the appropriate stock. For example, heavy text and cover paper
00:12 are going to work the best, and a stock with a smooth finish is really good
00:16 because you want to maintain that metallic look if you're using a metallic foil.
00:22 Or if you're using one of the clear foils, again you want a smooth finish.
00:26 If you try to iron out that stock in order to maintain a smooth finish that's
00:30 going to require higher pressure. And because the stock is then placed under
00:34 higher pressure, that's going to cause an impression on the reverse side of the stock.
00:39 Which may not matter if you're doing this on the cover, but it's something to
00:42 consider, especially if you're going to use both sides of the stock.
00:46 You want to avoid trying to apply hot foil to coated or varnished stock, because
00:50 there's heat involved, gases are given off when that heat is applied to make that
00:54 foil adhere to the stock, and gases get trapped and cause bubbling.
01:00 And that would sort of defeat the purpose. You want to have that nice smooth metallic
01:04 or clear finish. Bubbles are going to mar that finish.
01:08 And for the same reason, you want to avoid applying foil on top of inks that aren't
01:12 wax free. And as you're creating your design you
01:16 have to remember that foil spreads a little bit, it sort of fills in narrow gaps.
01:21 And so for that reason you want to avoid fine type and very tiny art details.
01:26 And when you're creating type you want to provide a little bit of extra space
01:30 between your letters so track your text out a little bit.
01:34 And you want to consult the printer and the diemaker, if your'e planning to
01:37 register foil to printed art, for that same reason.
01:42 And as far as achieving contrast and contour, metallic and opaque foils look
01:46 great on dark stock. That's not to say that you can't put them
01:50 on light stock. But you can make some really interesting
01:53 effects by applying metallic, or opaque foils such as white foils, on dark stock.
01:58 And then on light stock, clear, pastel, or pearlescent foils make for really nice effects.
02:04 Sort of similar to what you could do with a spot varnish, but with a higher shine.
02:08 And the pearlescent and pastel foils are almost like using a tinted varnish but
02:12 with a little bit extra. Now cold foil is different from hot foil,
02:16 not just in the name, but cold foil is not a separate process.
02:20 It's not something that's applied after the job is printed, it's something that's
02:24 actually applied in line on press, and that means that it's easier to register to printing.
02:30 It can be over printed, so you can print the cold foil in much the same way as you
02:34 print in ink, and then come back on top of it with process inks or spot inks.
02:40 And that means that essentially you can have an endless spectrum of color
02:43 metallic, it gives you a lot of flexibility.
02:47 In the past the reflectivity of cold foil wasn't quite that of hot foil, but it's
02:50 getting better all the time. So if you want to put metallic effect into
02:55 a piece, but maybe you don't want the expense or the complication of using hot
02:59 foil, you might consider using cold foil instead.
03:04 And you might find that that really serves your needs.
03:06
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Foil limitations
00:01 So, here are some things to think about as you contemplate using foil stamping in a project.
00:07 Coated stock is usually okay, foil stamping works very well on coated stock,
00:11 it gives it a nice smooth surface. But varnishes can present a problem.
00:17 And that's because they can keep trapped gases from getting out.
00:21 And that means that you might see bubbling under your foil, and you don't want that.
00:25 You don't want those ugly bubbles marring that nice, smooth surface.
00:30 There's heat and pressure involved in applying hot foil, and sometimes that can
00:33 cause color changes on the stock, especially yellow or brown stock.
00:38 Darker stocks tend to cause a little bit of color change.
00:42 Some foils can change color too, slightly after application.
00:45 Don't expect to find hot foils in every Pantone color, but there is a huge range.
00:51 The most efficient way to use foil stamping is to foil isolated areas, you
00:54 know a medallion on the cover or a logo on the back cover, something like that.
00:59 Now there are some systems that can do what's called indexing, and that means hat
01:03 they can optimize the foil usage and they can reposition so that the foil can be
01:07 used in the most efficient manner. But for example, doing something like just
01:12 foiling the border around a large area, essentially that wastes the foil inside.
01:18 Again, there's a possibility that they can index, that they can use that foil for
01:21 another purpose, but you may find that this is going to really add to the cost of
01:24 the job. If you have your heart set on having
01:28 something like a metallic border around, let's say a poster, you might think about
01:31 instead of using hot foil, use cold foil. And cold foil, in essence, means you apply
01:37 an adhesive on press in much the same way you apply an ink, and then the foil is
01:41 adhered to that. As far as holding sharp details, you're
01:46 going to find that metallic foils are a little bit sharper than pigmented foils
01:49 such as the opaque white foils or pastel foils.
01:53 If you're checking a proof keep in mind that there may be a fee for proofing a
01:57 foil stamping job. You're looking for problems like this:
02:01 feathering, it's like a little skirt around letters and other art details,
02:05 color changes, has the stock changed color?
02:09 Has the foil itself changed color? Because of the heat and pressure involved.
02:12 Is there scuffing as the pieces fall together?
02:16 Is the foil starting to come back off? Is the foil cracking, wherein it should be
02:20 adhering to the surface of the stock? Is it peeling off?
02:23 It's not sticking to the area it's supposed to stick to.
02:26 Are you getting the adequate pigment strength?
02:28 Is it the color that you expected? And of course you're always looking at the
02:31 edge definition. Keep in mind, of course, like any aspect
02:35 of printing, this is a physical process and you're sort of at the mercy of the way
02:38 a particular foil behaves on a particular stock when you're trying to create a
02:42 particular piece of artwork. But planning ahead and learning what the
02:48 limitations are ensures that you and your foil stamper are going to be happy about
02:52 the results.
02:54
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Creation of art for foil dies
00:01 When you're creating artwork that's going to be used for foil stamping it might be
00:04 nice to keep in mind how foil stamping works.
00:08 The foil actually has a bit of adhesive on the back and that's what makes it
00:11 initially stick on the paper, but what makes it stay there is pressure and heat
00:15 from a die and a counter die, and what you're creating artwork for is that die.
00:22 Ideally you should supply black and white vector art.
00:25 If you're going to supply an image it should be a high resolution bitmap, at
00:29 least 600 pixels per inch. And when I say bitmap I mean an image that
00:33 has only black and white, no grayscale. Don't have any screens, no textures,
00:38 anything like that. It really needs to be solid areas.
00:42 And as you create text provide a little extra space between the letters and keep
00:45 in mind that there's always sort of a little fringe where foil is applied, a
00:48 little fringe around the outside, and that could result in letters that are too
00:52 close, sort of running into each other. And you'll see that same effect inside
00:58 text with small counters so keep that in mind as you choose the font that you're
01:01 going to use. This is another reason why you want to
01:05 avoid anything like cross-hatching, or similar textural effects.
01:09 You're best off with just solid shapes. Convert all your text to outlines.
01:14 And then provide whatever the die maker or the printing company asks you to supply.
01:18 Whether it's an EPS, or an Illustrator native file, AI, or a PDF file.
01:24 If you're using multiple colors of foil. Clearly identify each color.
01:28 It's helpful if you know the official name of the color.
01:31 But if you don't, at least name it something that's obvious, that's in
01:33 keeping with your plan. And create those as spot colors.
01:38 And it doesn't hurt to put them on separate layers either.
01:40 Keep in mind that any errors might result in a reprint because you can't unfoil a
01:44 piece of paper. So plan far ahead, consult with the
01:48 printer, consult with the die maker, and make sure you understand the best way to
01:52 create and supply your art so that the job is successful.
01:56
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5. Die Cutting Basics
From basic pocket folders to origami
00:01 When you want to take your printed project beyond the plain old rectangular, then you
00:04 enter the world of die cutting. Even if you're creating something as
00:08 seemingly simple as tabbed dividers. We see them all the time.
00:12 But how do they get that shape? Well, they're die cut.
00:15 And that means that a die has to be created and the job has to be planned with
00:18 that in mind. And of course novelty shapes.
00:22 Pretty much any shape you can think of can be die cut.
00:25 There are some limitations. Some small details can be hard to hold.
00:29 But you can see from looking at these pieces, they're very different, all of
00:32 them, from the simple rounded rectangle on the little cards, to the paintbrush, to
00:36 the motorcyclist, to the sandwich. Great variety.
00:41 And something that you immediately notice. That's something that you sort of pick out
00:43 of the pack. Stands apart from all the dull old
00:46 rectangular pieces. And if you really want to hold fine
00:49 detail, we're seeing more and more laser die cutting.
00:53 Now, there's no actual die created. It really is a laser vaporizing the paper.
00:58 And that means that you can hold very small detail.
01:01 There's some limitations. It's a slow process in the sense that you
01:03 can only do one piece at a time, but you can do something with this that you really
01:07 couldn't do with a conventional metal die. So you can see there's a wide, wonderful
01:12 variety of possibilities with die cutting. It takes some planning.
01:16 You should talk to your printer, and if you're dealing directly with the finishing
01:19 company, of course, you want to consult with them early in the process.
01:23 But when you see things like this, I hope it inspires you to go beyond the plain old rectangle.
01:28
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Examining a cutting die
00:01 This is probably the first time you've seen a cutting die, so let me explain
00:04 what's going on here. This is a cutting die that's going to cut
00:08 out some little cards that have rounded corners on them, so, the job has been
00:11 printed with the cards in position, 12 up And let's take a look at one of the cards.
00:17 They're little rounded rectangles. These are cutting blades, so, you might
00:20 want to think of them sort of like razor blades that have been shaped.
00:25 And when this dye presses into the paper, it's going to cut out the shape of that card.
00:29 But you notice that there are other little blades that are attached to the cutting
00:32 blades, so what do they do? Well, when the card is punched out of the
00:36 paper, tey need an easy way to pull off that excess paper, the waste.
00:40 So those other little cutting blades allow them to punch little lines into the paper,
00:44 and easily strip off the excess. And so that's a process called stripping.
00:49 And that's to pull off that excess. That waste paper.
00:52 And those little pieces of foam that you see around the blades.
00:55 Serve as a way to sort of absorb that pressure as that die hits the paper and
00:58 they keep the paper in position, they keep it from squirming so that the cut is precise.
01:05 So how does a die like this come in to being?
01:07 Well you can see the plywood background. How do those blades get in position and
01:11 those little pieces of foam. Well, in the olden days every bit of this
01:15 was done by hand. Careful measuring, manual shaping of those
01:18 blades, mounting those blades in that plywood base.
01:22 Now there's a lot of computerized control. So, you see CAD programs that create the
01:26 dyes and they route little troughs in that plywood and those little troughs serve as
01:30 the positioning places for those blades. Those same CAD programs also drive
01:36 machines that bend those blades so things that used to be done by hand are now
01:40 accomplished by machine, but not every bit of it.
01:44 Those blades have to be manually mounted in these little troughs.
01:48 Those little pieces of foam have to be manually positioned but that's not a
01:51 mechanical process. There really still is a lot of
01:54 craftsmanship involved in making a die like this.
01:58 The die maker has to understand how that die behaves when it presses into the stock.
02:02 He has to know exactly the right height for that little blade to sit in that
02:05 little trough, so there's quite a bit of tweaking that happens.
02:09 So even though we have precision because of computers we still need that artisan,
02:13 we still need that craftsmanship and that's what to me really makes die making
02:16 an art.
02:18
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Laser die cutting
00:01 Another method of paper sculpture is to use a laser and we're seeing more and more
00:04 of this. It's a direct process wherein a laser
00:07 essentially burns and evaporates parts of a piece of paper.
00:12 Now it's a one off process meaning that it's one piece at a time.
00:16 But there are some advantages. There's no die tooling involved because
00:19 there's no die cutting. And it can hold very fine detail, it's a
00:23 digital process, so that means that if you need to make a modification to a job, you
00:27 don't have to recreate a die and start all over.
00:31 You can just recreate the digital file that's driving the laser.
00:35 What's this used for? Well, projects like special event pieces,
00:38 wedding invitations, business cards, I've seen a lot of greeting cards this way.
00:43 How do you supply your artwork? Well, really it's just art that you would
00:47 create in illustrator. You do have to keep some things in mind.
00:51 Think of it as being sort of like a stencil.
00:53 You have to have little bridges to hold little pieces in.
00:56 In other words think of doing the letter O.
00:58 How would you hold the center of the O in place?
01:00 You have to have a little bridge across it.
01:03 Even though it can hold very small detail, they tell you that usually your smallest
01:06 feature ought to be about 3 quarters of a millimeter.
01:10 But if you look at a metric ruler, you'll see that's really pretty small.
01:13 It doesn't replace high-volume die cutting because you have to do one piece at a time.
01:17 And especially if you're creating simpler simpler pieces, if you're just cutting out
01:21 a square, really should use a conventional die.
01:24 But it has some advantages. If you want to do just a short run, or
01:27 especially if you want to do personalized jobs, and we see this often with projects
01:31 like wedding invitations, laser cutting is probably the way to go.
01:35 And to be able to render beautiful detail that really wouldn't be possible with
01:39 conventional die cutting, laser cutting makes some things possible that otherwise
01:42 you really couldn't do.
01:45
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Design considerations for die cutting
00:01 When you start to consider using die cutting in a job, it's helpful if you sort
00:04 of think, like you are creating a stencil and here's why.
00:07 Here's the kineteco logo, and we were thinking it would really be fun to die cut
00:11 that, and so the director of marketing said, "let's get this die cut." We pointed
00:14 out to her that, if we just cut that out, the little centers of the Es and the
00:17 little counter in the Os are just going to fall out, so that's not going to be
00:20 satisfactory, might be kind of cute but we're just not crazy about the results.
00:28 So we struck a compromise, so instead we're just going to die cut the little
00:32 arcs and then we're going to foil stamp the logo text.
00:37 We still get something that looks really nice, and we get to maintain the shape of
00:40 the logo completely and we don't loose the little hearts of the Os and the Es.
00:44 So you have to think about that mechanical process when you think of creating art for diecutting.
00:50 And you also want to avoid very fine detail, although if you consider using
00:53 laser cutting, you can maintain very small detail.
00:57 But, the limitations of laser cutting are that you can only do one piece at a time.
01:02 It's great for short runs, it could end up being prohibitively expensive for long runs.
01:08 And when you have colors that intersect right at the corner of a die cut then you
01:11 have to create what's called a beveled bleed.
01:15 So here where we have the purple background and the little yellow flower
01:18 meeting right at that little die cut line, we have to change the shape of that
01:21 artwork so that if there's a little bit of misregister between the printed piece and
01:25 the die cut then it's not immediately apparent.
01:30 You also have to consider how the piece is going to be used.
01:33 Is it going to be mailed? Well, I don't think you want to mail it
01:36 loose, because it's going to be handled and you don't want it to get torn up.
01:39 So of course, you would enclose it in an envelope.
01:43 Is it a piece that's likely to experience frequent handling?
01:46 Well, then little sharp pieces that hang out, like the little part of our
01:49 kinematical logo, that could be problematic.
01:52 Those are going to to get snagged on something and get bent and mess up our artwork.
01:56 And if you're considering dye cutting stationary, you can do it, but I would
01:59 keep a fairly simple edge because you have to consider what's going to happen when it
02:03 gets pulled into a printer. It could cause a paper jam, or it could
02:08 sort of wreck your delicate artwork. That's not to say don't use die cutting,
02:12 but you just have to consider what's going to happen to the piece after it leaves the
02:15 printing plant. How is it going to be handled?
02:18 Is it going to be mailed? And you don't want all your nice work to
02:21 go to waste. So you always design in anticipation of
02:24 the way that piece is going to be produced and handled.
02:27
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6. Designing Die Cutting in Illustrator
Creating a dieline in Illustrator
00:01 I'm almost finished with the design of this card.
00:03 But before I send it to the printer I need to do two things.
00:06 I need to create artwork for the die line that's going to be used to cut this out.
00:10 And then I'm going to need to add bleed. So first, I'm going to create the die line.
00:15 You can see how the layers are created. All the artwork's getting almost ready for print.
00:20 And the pieces that I need to create the die line are actually already in the artwork.
00:24 It's going to cut out like this, it's going to go around the rectangle and then
00:27 the little yellow petals are going to pop out.
00:31 First thing I'm going to do is create a die line layer.
00:34 Which of course I'm going to call, die line.
00:36 And then I'm going to duplicate the rectangle and the little yellow petal
00:39 shape into that layer and use them as the basis for the die line.
00:44 So, I select the little rectangle. And I don't want to move it.
00:48 I want to keep that original, of course. So I hold down Option or Alt, and drag up.
00:53 And that duplicates that shape. Same thing with the little yellow petals.
00:57 Option or Alt, drag it up. And you can see that the original shapes
01:01 are still in position. But now I have the duplicate of them in my
01:04 die line layer. I'm going to turn off all the other layers
01:07 so I can just concentrate on this one. Now, because it's going to be a die line,
01:11 I don't need the shadow. So I'm going to get rid of that, by going
01:14 to the Appearance panel, and just selecting Drop Shadow.
01:17 And hitting the little trash can. What I really need is the perimeter of
01:21 this shape. That's what's going to constitute the die line.
01:25 I can combine these two shapes two different ways.
01:27 I can use Pathfinder, or I can use Shape Builder.
01:30 The results are the same. It's really just which method you prefer
01:33 to use. So first, I'll show you Pathfinder, under
01:35 Window of course. I just select both shapes, and use the
01:39 Unite option on that first row. Now it's just one shape.
01:44 I'm going to undo so that I could show you the Shape Builder, which is a really fun tool.
01:48 Select both of the shapes again, get my Shape Builder and then you just drag from
01:51 one shape into the other. In this case it won't matter which one you
01:55 use as the first shape. There we go, again two different methods,
01:59 but the same results. But what I need now is a die line color.
02:05 I need a special color that indicates to the printer this artwork is used for the
02:08 die line. So in the Swatches panel, I'm going to
02:11 make a new swatch. Now, the look of this really doesn't matter.
02:16 It does need to be a spot color and, of course, I think it makes sense to call it
02:20 die line. And it really wouldn't matter whether I
02:23 chose RGB or CMYK. This document, of course, is CMYK color mode.
02:28 But I tend to use RGB. This is, again, just personal preference,
02:31 because I like to make a bright green color that's really obvious.
02:35 And it's clear that it's not part of the art work.
02:37 But again, the color you choose, I think, should be a contrast to your underlying artwork.
02:42 And it should be something obvious. Just make sure that it's spot color and
02:45 make sure that you name it something fairly obvious.
02:49 I don't need a fill, so I'm going to change the Fill to None, and I'm going to
02:52 change my Stroke, of course, to my new die line color.
02:56 Now, back in the layers panel, I turn everything else back on, and there we go.
03:00 Now at this point, I don't have bleed. That's something I'm going to show you in
03:04 another movie. But at least I have my artwork.
03:07 And I have my die line created. One more thing I'd recommend that you do.
03:11 Even though the artwork for the die line is going to be output separately.
03:14 It's not going to be part of the printed piece.
03:17 Just to be sure, here's a good practice. Go up to Window and Attributes.
03:21 And now that's one of those panels you don't go to all the time, but one thing
03:24 you can do here is really valuable. You can set that stroke to overprint and
03:28 what this means is that if they output this, we know that it doesn't knock out
03:31 anything that's underneath. It's just a little nicety, it's just good
03:36 habit and one way to check what you have is to go to Window, go to Separations Preview.
03:42 You have to turn on over print preview to activate separations preview.
03:46 And you make sure that you have any spot colors that you need.
03:49 Make sure you don't have any that you don't need.
03:51 And if I turn off CMYK that leaves just my die line.
03:54 I'll turn off my die line, there's my CMYK.
03:58 So even though I don't have bleed yet, which means that this is not ready to send
04:01 to the printer, I've got a really good start so that I can finish up this card
04:04 and send it off for printing and then ultimately die cutting.
04:08
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Handling a complex bleed
00:01 I'm almost finished with this job. I've completed my design.
00:04 I've created my die line. But I have to remember to add bleed before
00:08 I send my job to the printer. Now if it were just a rectangular card,
00:11 that would be really easy. I would just add an eighth of an inch all
00:14 the way around. But what makes it a little bit tricky is
00:17 the intersection of this yellow petal shape and this purple background.
00:22 Well, let's do the easy part first. So over here in the Layers panel.
00:25 I'm going to pull this loose and I'm just going to hide everything but my purple background.
00:30 Select that. And my favorite way to do this is with the
00:33 Transform panel. Window > Transform.
00:37 And, of course, you can also use this little link up here.
00:40 You want to make sure that it's centered, with that reference point in the middle selected.
00:45 Now I could do math in my head or I could make it easy on myself and let Illustrator
00:49 do the math. I know I'm going to add an eighth of an
00:52 inch left and right and top and bottom. To add left and right, it's going to be
00:56 actually a total of a quarter of an inch. So here, in the Width field, I can just
00:59 click after the current measurement. Type a plus 0.25.
01:03 There we go. And same thing for the height.
01:06 Just plus 0.25. it's a little bit easier.
01:10 You know, let Illustrator help you when it can.
01:13 Now we get to the tricky part. And that's dealing with these petals.
01:16 So, the first thing I'm going to do is turn on my guideline and lock it.
01:20 I'm going to hide the parts that I don't need to deal with.
01:25 I do want to see my background just so I can be sure I'm doing the right thing.
01:28 And here's what I need. I need extra on this yellow shape all the
01:32 way around. I can't afford to put it all the way
01:35 around the complete shape, or I'm going to mess-up the designs.
01:38 So I just need Bleed over part of this. What I'm going to use is something called
01:42 Offset Path. So, first I'm going to duplicate my
01:45 original flower so I don't mess it up. And I can do this by coming over here and
01:49 saying duplicate path or I could use my little new object down here.
01:54 So, I'm going to drag this down to the new object and it duplicates it.
01:59 Now, having 400 paths called path makes it a little hard to figure out who's who.
02:04 So I'm going to name these pieces so that I can recognize them.
02:07 So this is going to be my original petals. And I'm going to hide that because I don't
02:13 want to hurt that. This is going to be my bleed.
02:17 (SOUND) So I'm going to select this shape and I'm going to use Offset Path.
02:21 Object > Path > Offset Path. By default, this is the figure that comes
02:27 up, but I want an eighth of an inch. So I'm just going to say 0.125, and there
02:32 we go. Now, it has a shadow on it, which I don't need.
02:36 So I'm just going to come over here to my Appearance panel, select that Drop Shadow
02:40 effect, and get rid of that. But you might notice that hey, I hid my
02:44 original, how can I still have a shadow? Funny things happen when you offset path.
02:49 It sort of duplicate sit for you even though that's not what you want, so I
02:52 actually have some shapes that I don't need.
02:54 I have this shape, which is the original configuration of the petals, so you know
02:58 what, I'm just going to get rid of that. Just hit my little Trash Can, there we go.
03:03 This is going to be my bleed. But, remember, I don't want to deform the
03:07 shape of this so I just need the extra out here outside my trim.
03:11 And I'm going to create what's called a bevelled bleed.
03:14 So this is the tricky intersection. If we have this yellow come right down
03:17 here to the trim. What if there a little bit off when they
03:21 trim it. Then I'll see a little yellow trim in here.
03:23 So that won't work. I can't have the purple come all the way
03:25 over to here, because I might have a little purple rim in the flower.
03:29 So the sensible thing is to create this beveled cut, and it may make more sense
03:33 after you see it happen. Several different ways I could do this,
03:37 but I think I'm going to use my pen tool, because I'll just have a little bit more control.
03:41 And before I do anything else, I'm going to name this, and this is going to
03:44 be my petal bleed. I'm a big fan of naming objects in
03:48 Illustrator so you can recognize them,e specially the next morning when you pick
03:51 back up working on something like this, so smart guides are going to come in really
03:54 handy here. I'm going to get my Pen tool.
03:58 Now right now if I draw it's going to draw a yellow shape.
04:01 You can see my fill color... I'm going to hit a D on my keyboard for default.
04:06 Now that would be an opaque white shape with a black stroke.
04:09 Then I'm going to hit my forward Dlash key or I could hit this little object here.
04:13 And that gives me a fill of none. What I like about this is I can see my
04:16 path as I draw it. But then I can see what's behind it while
04:19 I draw too. So I'm just going to start out here.
04:22 And smart guides again are going to help me out.
04:25 I'm going to hit, this little dip right here where the pedals meet.
04:28 And I want to hit this little point where that rectangular shape is going to meet
04:31 the pedal shape when it turns. Boy, I love smart guides.
04:38 And then what happens down here as long as I draw it big enough that it can sort of
04:41 saw off that Unneeded part of the petals, I'm good.
04:45 Now I'm going to use Pathfinder to get rid of that unwanted part of the shape.
04:49 So under Window, and then Pathfinder, I already have this little shape selected.
04:55 When I hold down Shift, I can select the flower.
04:57 And I'm going to use minus front. There we go.
05:01 Now I just have the part of the flower that I need.
05:03 And this is what I meant when I said a beveled bleed.
05:05 See how it hangs out here? So now we've got a little margin of error
05:08 here if they're a little bit off, and they won't be of course.
05:12 But if they are a little bit off, it's not going to be obvious when the card is trimmed.
05:16 So let's turn some things back on and see what we have I believe this is going to work.
05:21 Now, if you're concerned about what happens to the shadow here ...
05:23 Gee, shouldn't I have the shadow all the way around?
05:26 Well, no, because it would sort of leak in here.
05:29 Again, you're trying to go for, I guess what I would call worst case scenario.
05:32 If there's a little bit of slippage. And I will tell you that printing and die
05:36 cutting are much more precise than they were, gosh, just ten years ago, but it
05:39 doesn't hurt to be a little paranoid. You want to honestly make it as easy on
05:44 the folks that are going to trim and print this as possible.
05:48 This is going to be great. This is going to be well behaved.
05:51 Lets turn everything back on and lets lean back and take a look.
05:55 So there's my little green dye line. I have adequate bleed.
05:59 I've done my little bevel trick here so that's its going to be much easier for the
06:02 printer and the dye cutting place to get this to work right.
06:06 Now ultimately you know when this prints, it's not going to be just one little card
06:09 in the middle of a sheet of paper. They're going to step them up.
06:12 There'll be several cards. But that's something that the printer does.
06:16 And how that's laid out is up to them. They'll work it out with the die place.
06:21 How they're going to lay out the die. That's not something you need to worry about.
06:25 Having all that extra art (UNKNOWN) around doesn't really matter, but you know what?
06:29 I tend to like to trim it off, so, I'm going to take my artboard tool and I'm
06:33 just going to trim this down a bit. Honestly, it's just a personal preference thing.
06:38 In truth, all that really matters is where there's occupied space but, I just think
06:41 this presents a little bit better. So actually my job is now ready to send to
06:46 the printer. Everything's in good shape I've provided
06:49 bleed I've given them a dye line. I think this job's ready to go and I think
06:53 its going to be really cute when its printed and trimmed.
06:56
Collapse this transcript
Sending Illustrator die-cut files to the printer
00:01 I finished designing this card, I've created the die line and now I'm ready to
00:04 send this to the printer, to have it printed and die cut.
00:08 Now, not all printers do their own die cutting, a lot of printers don't build
00:12 their own dies, and it's often a collaboration between the printer and a
00:15 finishing company. But in this case, my printer actually does
00:19 their own die cutting. They've already had the die created based
00:22 on the die line art that I gave them and now, it's time to send them this artwork
00:25 so that they can print the job, and then die cut it.
00:30 They're going to lay it up, they're going to have multiple instances of this
00:33 card on the press sheet. But that's not something I do, because
00:36 it's up to them, they know what size stock it's going to run on, they understand
00:38 their presses the best, it's just my job to give them a good, healthy file.
00:43 So they've asked me to send them a PDF and of course, my native Illustrator file.
00:48 When I choose File > Save a Copy, and I'm going to do that to save my PDF.
00:53 Why would I do that? Well, funny thing, Illustrator can make
00:56 PDFs without having to use a print process or an export process.
01:00 Under the hood, Illustrator files kind of are PDFs.
01:04 So here I'm going to choose Adobe PDF, click Save, now the default is something
01:08 called Illustrator Default and it's sort of an odd bird, it's really sort of a two
01:12 for one file, it's really your Illustrator file inside a PDF.
01:18 The good news about that, is that, Illustrator can safely open up a PDF like
01:22 that because it's really going to reach inside and just get that native
01:25 Illustrator content. But that's going to add to the file size
01:29 and that's not really what my printer wants this PDF for, they're not going to
01:32 be editing it. This PDF is going to serve as sort of the
01:36 digital equivalent of when we used to send lasers.
01:39 Remember when we used to print lasers and send with our jobs?
01:41 It's still a good idea, but for this I'm going to say I want it to be high quality
01:45 print, even though it's not going to get printed.
01:48 This is not the file they're going to use for printing, they're just going to use
01:51 this as an on-screen reference, just, for the mechanics of the file.
01:55 So, to keep the file a little smaller, and because editing isn't going to happen, I'm
01:59 going to uncheck Preserve Illustrator Editing Capabilities, Optimize for Fast
02:03 Web View does not make it a smaller file, I'm going to uncheck that.
02:08 As far as marks and bleed go, all of the bleed is actually inside my file
02:11 dimensions and I don't need to add marks. Again, it's just a PDF that's just for
02:17 visual reference on screen and I'm going to click Save PDF, and then of
02:19 course, Illustrator's going to squawk a little bit, because it says, you unchecked
02:23 Preserve Illustrator Editing Capabilities. It's not a problem, and I know that, so
02:29 I'm going to click OK. Now to save my Illustrator file, I just
02:33 say File > Save As, I'm going to put it back in that same job folder that I'm
02:36 going to send to the printer, and it gives me this little squawk about spot colors,
02:40 but this is a process color job. What's my spot color?
02:46 It's my die line, because that's a spot color.
02:49 This doesn't mean that I have a problem, it's just Illustrator being polite saying,
02:52 are you sure you want to do a spot color, yes I am.
02:55 And, if these things annoy you, remember you can always check this Don't Show Again box.
03:00 So when I click Continue, I'm just going to click OK because all the default
03:04 options are going to be fine. So what happens when this lands at the printer?
03:08 What do they do with it? Now, this is not an actual press sheet but
03:12 I wanted to give you sort of an idea how a job like this might print.
03:16 Now, we can still see the die line, that would not print, that's something that's
03:19 just a guide for the die creation. But, I just wanted you to see how the die
03:23 relates to the printed artwork. And it's always a goal to try to make the
03:27 best use of the piece of paper. So, here's something that could happen
03:31 with a job like this, so that the printer can make just one cut, to separate these
03:35 cards, there's no bleed where these two cards meet.
03:39 So that would just be a single cut. And as far as how close to put a row of
03:42 cards next to the next row of cards, again, it's just going to depend on the
03:45 press that they're running on, the size stock that they're printing on and how the
03:48 die is going to be built. Now, it's not up to you to build this kind
03:53 of layout, that's something that's going to happen at the printer.
03:56 You're going to provide them with just that one single card, and it's up to them
04:00 to determine the position for these, what we called ganged printing for these cards.
04:06 And they're going to make that arrangement based on a collaboration between them and
04:10 the die cutting company. Now, some printers do their own die
04:13 cutting, a lot of them don't build their own dies, though, so they would have the
04:16 die cutting company prepare the dee for them, supply them the die, and then the
04:19 printing company performs the die cutting. Some printing companies don't do this
04:25 fancy die cutting at all, they'll send this entire job out once it's printed to a
04:28 separate die cutting company. They'll make the die and they'll perform
04:32 the die cutting. So it's important of course, that the
04:35 printing company and the die cutting company communicate with each other, and
04:38 that the die line of course, lines up with the final ganged up art work.
04:43 So yes, it's a complex process, but the results are really nice.
04:46 So, I would suggest that if you're entertaining the notion of creating
04:49 something like this, of course, you want to talk to your printer, but go to the
04:52 printing company, watch something like this run, watch it come through the press
04:56 and then either, go to their finishing department and watch a die cutting job
04:59 being handled, or go to a finishing company and watch a die cutting job being handled.
05:06 It gives you an appreciation for the craftsmanship that's involved but, I think
05:09 you also find that in addition to being sort of an education, it becomes sort of
05:12 an inspiration when you see what's possible, when you change the shape of
05:15 paper I think it gives you some great ideas for future projects.
05:21
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7. Designing Die Cutting in InDesign
Creating a dieline in InDesign
00:01 When you're working on a project that involves dye cutting, do you do it in
00:04 Illustrator or do you do it in InDesign? Do you create part of it in Illustrator
00:08 and part of it in InDesign? To a certain extent, it's really a matter
00:11 of personal preference. For me though, if I'm building something
00:15 this complex with this little petal edge, and then I need to provide bleed.
00:20 And I have to have that little bevel bleed where those 2 colors meet.
00:22 I prefer to just create the whole thing in Illustrator because all the tools are
00:26 there, and I can just do it all in one place.
00:30 There's no reason why you couldn't create it in InDesign, just be a bit more frustrating.
00:34 But for simple projects, there's no reason why you couldn't build it in InDesign.
00:38 So I have a project here that's really simple.
00:40 It's just essentially rectangular cards with little rounded corners.
00:44 So, there's no reason why I can't do it right here in InDesign.
00:47 But there's still a couple of things you should know.
00:48 First thing is, don't build a lonely little card in the middle of a letter size page.
00:54 Always make your page to the trim size. Now with the daisy card you saw a minute
00:57 ago, that would be pretty tough to do. But here it's a you know, fairly uniform
01:01 card so we can do that here. First thing I'm going to do, is change my
01:06 document size, so File, Document Set up and the width is going to be 4 and a
01:10 quarter and the height is 1 and half, and I'm going to need bleed, but rather than
01:14 typing I'm just going to hit my up arrow twice.
01:20 Now if you're working in points and picas you have to hit your up arrow a few more times.
01:25 But I like being able to just do that, and not have to type.
01:28 Now it's the right size, but I have this gigantic margin staring me in the face.
01:33 Doesn't really hurt anything. But if it annoys you, you can change it.
01:37 I'm going to do that on the master page, so that it occurs on all the pages in the document.
01:40 And that's because this is ultimately going to be a document containing 4 cars.
01:45 So I'm going to put some things in place on the master.
01:47 And while I'm in the master, I'll fix the margin.
01:50 So I double click on the master. Go up to layout.
01:54 Margins and columns. And then set that to zero.
01:57 And there we go. Now, what I need to do is create that die
02:01 line artwork. That's going to appear on every page.
02:05 So I might as well do that on the master, too.
02:07 First I need to create a dye line color. So in the Swatches panel, going to make a
02:11 new color swatch, of course I'm going to call it dye line, I'm going to make it a
02:15 spot color. Now, it could be any color because it
02:19 isn't something that's going to print. It's just essentially for the geometry.
02:24 But, my habit is always make it RGB and bright green.
02:29 Just makes it easy to find it in the midst of other art work, although of course if I
02:31 were working on a bright green project, I would probably make it something else.
02:35 But it's just anything to make it obvious. And now I'm going to create the die line.
02:41 I know that it has to be essentially rectangular but that it has the rounded corners.
02:45 I could do it either with my rectangle frame tool or my rectangle tool, it
02:49 doesn't matter. I suppose the rectangle tool gives me a
02:52 bit of a head start because it already has a stroke on it when you build it, so there
02:55 we go, corner to corner, and smart guides of course help it snap to the corners.
03:01 And now I'm going to give it the rounded corners.
03:03 Under Object... Corner Options.
03:06 If Preview isn't checked, check it. If you check it once it stays checked,
03:10 which is nice. I'm going to choose the Rounded option,
03:13 and then there's my quarter inch. And I want to separate that from the rest
03:18 of my artwork. So in my Layers panel I'm just going to
03:22 re-name this die line. And I'm going to create a new layer and
03:28 drag it below die line. It doesn't matter whether it's above or below.
03:33 Remember, it's not going to be something that prints.
03:35 Where you position it in the layers panel is just really going to be whatever's
03:38 easiest for you. I tend to put it at the top layer because
03:41 I know I'm going to put artwork in this document that's going to fill up the page,
03:44 and I want to make sure that things fall within it, so it's just easier to see.
03:49 If it's up above everything else. And now, I'm going to create the other 3
03:53 pages because this is ultimately, as I said, 4 cards, so I'm going to insert 3
03:56 pages and end design because it's so polite, thinks you want to start on one of
04:00 your newly added pages, but nope I want to go back to page one and now I'm going to
04:03 bring in the artwork. So I've created the artwork in
04:10 Illustrator, so I'm just going to choose file place, and in the assets folder,
04:16 there they are. I could get them one at a time or I can
04:21 take advantage of the fact that InDesign lets me place multiple artwork at the same
04:24 time, so I'm going to choose Open It loads up my cursor with 4 of my little graphics,
04:28 and you can see the number 4. Of course you can choose to place them in
04:34 a different order, but I like the way they are, so I'm just going to click and they
04:37 already have bleed applied. I very cleverly added that when I was in Illustrator.
04:43 And then I could just go through from page to page, place my artwork.
04:48 By the way, if you look at the cursor, you might notice that it looks like a little
04:51 acrobat carousel. That's sort of suspicious, isn't it?
04:55 That's because, under the hood, Illustrator files are really sort of PDFs.
04:59 So. Don't let that surprise you.
05:01 Now, they look really ratty, because you're looking at, you know, your typical view.
05:05 So we want to make sure that it's really going to look good when it prints.
05:08 So I'm going to change my view by choosing, view display performance, and
05:12 high quality display. And then I'm going to switch to preview mode.
05:17 And I can do that by just pressing the w on the keyboard.
05:19 And I just want to make sure that things fall within trim the way they should.
05:23 So I make sure that my artwork is going to trim out all right.
05:26 That looks good. And I can actually zoom out by hitting Cmd
05:29 or Ctrl minus, and scroll up. Yep.
05:33 That looks good. That looks good.
05:35 I think we're in good shape. So again, for something as simple a this,
05:38 I could have built it in Illustrator but it's just as easy to finish it off in InDesign.
05:43 I already had the artwork created in Illustrator and it was easy to create the
05:46 dye line in InDesign. And because it's going to be 4 separate
05:50 cards, everything's already in place. And when I get ready to send it to the
05:54 printer, everything's already done.
05:56
Collapse this transcript
Sending InDesign die-cut files to the printer
00:01 I'm finished with this job and I'm ready to send it to the printer.
00:04 And what they want is a PDF that they'll use as just sort of a visual reference,
00:07 sort of the equivalent to the old sending printed lasers.
00:12 And then of course they want my application files.
00:14 They want my InDesign file and all the support art that I need to make that
00:17 InDesign file print. Now some printers will ask you to send a
00:21 print ready PDF but, even then, they might want to have your application files just
00:25 in case they need to change anything. So for my printer, I just need a high
00:30 quality print PDF and, then, my application files.
00:33 So to create my PDF, I'm just going to go to File > Adobe PDF Presets, choose the
00:38 High Quality Print. And it's going to go in my folder that I'm
00:42 creating to gather up all the files I'm sending to the printer.
00:46 The Optimized for Fast Web View and Create Tag PDF options honestly have no bearing
00:50 on what it looks like on screen. How fast the PDF is made.
00:54 I just always un-check those. I do want to make sure though that it
00:57 includes my marks, and it includes bleed. So again, this is just going to be used
01:02 for a visual reference. It's not going to be used for print.
01:06 That's a background process, but this is a fairly light file, so that didn't take
01:09 very long. So what's going to happen at the printer?
01:12 Well once they have my file and they've pre-flighted it and everything's okay,
01:15 they're going to gang these up, or you'll hear it called imposition, ganging,
01:19 multiple terms in the print industry. But they're going to print multiple cards
01:24 all on the sheet. And how do they determine that arrangement?
01:27 Well it's based on the size of the stock, or the press that it's running on.
01:31 And in case like this that's die-cut, it may be based on the limitations of the
01:35 machine that's going to be used to die-cut it.
01:38 This is not something you have to worry about.
01:40 You don't have to put these in position. It happens at the printer.
01:43 So you can see all the little cards are in position.
01:46 Now you can actually see the die line here but this is again not a real press sheet.
01:50 it's really just the kind to give you the thought.
01:53 How the die line relates to the finished piece.
01:56 We wouldn't see the die line on the printed piece.
01:59 Once the sheet's printed, it's going to either go to the bindery department of the
02:02 printing company if they do their own die cutting.
02:05 Or it's going to go to a separate die cutting company if they do the die cutting.
02:09 So I would always encourage you to tour the printing company, and see how these
02:12 processes take place. Especially jobs that involve die cutting.
02:16 It's really neat to see that solid sheet of paper become interesting little shapes,
02:20 it's almost like origami when it's cut out and I think you find again, it sort of
02:23 inspires you to think of ways you might want to handle future jobs.
02:28
Collapse this transcript
Conclusion
What I hope you've learned in this course
00:00 I hope that seeing some great examples of die cutting and embossing and foil
00:03 stamping will make you want to explore these processes more deeply.
00:08 The finishing craftsman can help you take a printed piece far beyond just ink on
00:12 paper, and the resulting shape and surface and shine make your project stand out from
00:16 all those dull rectangular pieces people see every day.
00:22 You can create a striking piece that they'll notice, in fact, something they'll keep.
00:26 Now you've seen that you can use the tools you already know, especially Illustrator,
00:29 to create artwork that the die cutting, embossing, and foil stamping artisans can
00:32 bring to life. Now these organizations provide resources
00:37 to expand your understanding of the specialty finishing processes and also
00:40 information about finishing related conferences and trade shows.
00:45 And to expand your skills in Illustrator and other graphics applications, of
00:48 course, you're going to find lots of great courses here on lynda.com including
00:52 Illustrator Essential Training, Illustrator One-on-One: Fundamentals.
00:58 Print Production Fundamentals, and Print Production Essentials: Spot Colors and Varnishes.
01:03 I really hope that this course has fired your imagination and taught you that these
01:07 elegant effects truly are within your reach.
01:11 So now I want you to go out and make me proud.
01:13
Collapse this transcript


Suggested courses to watch next:

Print Production Fundamentals (4h 26m)
Claudia McCue



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