Letterpress Die Cutting FAQ

Letterpress die cutting uses a thin steel rule die to cut and score one sheet at a time. This method is used for those designs with a critical register of bleeds with a minimum of wrap over the fold and those with minimum image shift of borders or other design elements. Letterpress work must be printed one-up on a larger sheet than for high die cutting because more gripper area is needed.

Grip and guide placement on the sheet is important for best cutting register. Look at the template right reading.

• Standard sizes: allow a minimum of 1/2″ grip at the bottom of the template, which is the edge of the sheet closest to the back panel of the envelope. Guide on either the left or right side flap.
• Small open-end catalog / policy sizes: allow a minimum 1/2″ grip on the left or right side panel edge of the template. Guide on either the seal flap top or end flap bottom.
• Large open-end catalog sizes: allow a minimum of 1/2″ grip at the end flap bottom of the template. Guide on either the left or right panel.
• Large open-side booklet sizes: allow a minimum of 1/2″ grip at either the left or right side seam. Guide on the seal flap top.

We have a large selection of letterpress dies that match our high die layout templates. Download from layout templates, then select the correct size from the letterpress sheet size guide. Specialty envelopes with custom flap designs, square envelopes and special sizes may also be made using a steel rule die. Email a PDF of the project to the production desk for expert help.

Letterpress die cutting has a minimum sheet size requirement. It is fine if your press sheet is larger, so generally no extra trim charge is needed.

The best stock weight for letterpress is 70# or 80# text with caliper between .005 and .0068 for standard sizes and up to .0085 for open-end catalog and large open-side booklet sizes.

Grain wrong stock curls up into the machinery causing jams, wasted stock and folding registration problems.

Machine settings can be changed to run grain wrong stock. Grain wrong setup is $100.00 for standard sizes and $100.00 for open-end catalog and large open-side booklet sizes.

The minimum for standard sizes is 300 or 10%, whichever is greater of the finished count. Allow 500 or 10% for open-end catalog and large open-side booklet sizes.

Full ink coverage requires no ink or varnish in glue and gum areas. Adhesion is not guaranteed if ink or varnish is printed in those areas.

The characteristics of certain stocks and inks may result in scuffing or cracking.

Please be sure to include a proof, sample, or blue line of the work with the stock, or simply email a PDF to our production desk. See the order page for what to include.

Our normal production time for most jobs is 7 to 14 days after the stock arrives here. Open-end catalogs and large open-side booklets can take 7 to 14 days. For rush orders, please call in advance to schedule.