A dense, scannable one-stop reference. Skim it before a meeting, a build session, or a quote.
Printing-Process Selector
| Job | Volume | Best process | Why |
|---|
| Business cards, flyers | 1–500 | Digital | No setup; cheap short runs |
| Business cards, flyers | 1,000+ | Offset (often ganged) | Low per-unit at scale |
| Brochures, catalogs, books | High | Offset | Quality + cost at volume |
| Personalized mail / variable data | Any | Digital (inkjet/toner) | Each piece unique |
| T-shirts, few colors | High | Screen print | Setup per color pays off |
| T-shirts, full-color / one-off | Low | DTG / DTF | No screen setup |
| Banners, posters, signage | Any | Wide-format inkjet | Large sizes, on demand |
| Labels, flexible packaging | High | Flexography | Fast on rolls/film |
Paper-Weight Quick Reference
| Use | GSM | ≈ US equivalent |
|---|
| Copy / letterhead | 80–100 | 20–24 lb bond |
| Quality flyer / text page | 120–170 | 32 lb bond / 60–70 lb text |
| Poster / brochure cover | 170–250 | 80–100 lb text / 65–80 lb cover |
| Postcard / menu | 250–300 | 90–110 lb cover |
| Business card / premium | 300–400 | 110–140 lb cover |
| Folding carton / packaging | 350–450+ | 12–18 pt board |
Note: Specify in GSM where possible — US "lb" depends on sheet size and is ambiguous. Text/book stock is bendy; cover/card stock is rigid.
Color, Files & Prepress Checklist
- Color mode: CMYK for print (not RGB). Flag RGB uploads.
- Bleed: 3 mm (0.125 in) past trim on all sides.
- Safe zone: keep text ≥ 3 mm inside the trim line.
- Resolution: 300 DPI at final size (photos); large signage 72–150 DPI OK.
- Pantone/spot: use for exact brand color, metallic, fluorescent.
- Total ink coverage: keep ≤ ~300% to avoid set-off/smearing.
- Fonts: embed or outline; black text: use 100% K, not rich black.
- File format: print-ready PDF (PDF/X) preferred.
- Preflight on upload: bleed, DPI, color, fonts, page size.
"X/Y" Ink Notation
| Notation | Meaning |
|---|
| 4/4 | Full color (CMYK) front & back |
| 4/0 | Full color front, blank back |
| 4/1 | Full color front, black-only back |
| 1/0 | One ink, front only |
Finishing & Binding Quick List
- Coatings: gloss / matte / soft-touch lamination; spot UV; aqueous.
- Folds: half, tri-fold (letter), Z-fold, gate, roll fold.
- Binding: saddle-stitch (≤ ~64 pp; pages ÷ 4), perfect bound (glued spine, thicker books), spiral/wire-o (lay-flat), case/hardcover.
- Cutting/shaping: guillotine cut, die-cut, round corners.
- Embellishments: foil stamp, emboss/deboss, spot UV (premium upsells).
- Other: scoring (clean folds), perforation (tear-off), drilling (holes), numbering.
Production Status Spine
Order Received
-> File Check (Preflight)
-> [Action Needed: bad file / proof?]
-> Proof Approved
-> In Production (print)
-> Finishing (cut/fold/bind/coat)
-> Quality Check
-> Shipped --> Delivered
(side: On Hold | Cancelled | Refunded)
Offset vs Digital — Break-Even Rule of Thumb
| Offset | Digital |
|---|
| Setup cost | High (plates + make-ready) | ~None |
| Per-unit cost | Very low | Flat per page |
| Cheaper when… | Long runs | Short runs / variable data |
| Crossover | ≈ 500–1,500 copies (varies by size/stock/shop) |
- Gang run = many jobs share one sheet & one setup → cheap short-run offset.
- Make-ready = fixed setup cost; the main reason short offset runs are pricey.
Key Formulas
- Markup % = (Price − Cost) ÷ Cost × 100
- Margin % = (Price − Cost) ÷ Price × 100 (always smaller than markup)
- Price from margin = Cost ÷ (1 − margin)
- Unit price = (Setup + Materials + Run + Finishing + Overhead) ÷ Qty × (1 + markup)
- Dim weight (metric) = (L × W × H cm) ÷ 5000 = kg (carrier divisor varies)
- Bill = greater of actual weight or dim weight.
Shipping Quick Take
| Mode | Use for | Threshold |
|---|
| Parcel (UPS/FedEx/USPS) | Small/light boxes | < ~68 kg (150 lb) |
| Freight / LTL (pallet) | Bulky/heavy runs, signage | Palletized or > 68 kg |
Sustainability Levers (biggest first)
- Right-size the run — overproduction is the #1 waste.
- FSC-certified / recycled stock; vegetable/soy inks.
- Print-on-demand (digital) to avoid dead inventory.
- UV-LED / water-based curing; efficient nesting/imposition.
- Back "eco" claims with real certifications, not slogans.
Talk Like a Printer (vocab line)
GSM · bleed/trim/safe · 4/4 · CMYK · spot/Pantone (PMS) · make-ready · gang run · imposition · preflight · saddle-stitch · perfect bound · spot UV · LTL · dim weight · click cost · aqueous coating · set-off · variable data