Key question
How does a sheet become a leaflet or a brochure?
After printing, the material is trimmed, creased, folded and bound. This finishing process determines how a printed product opens, reads and feels in the hand. You need to know the type of fold and binding as early as the design stage, as they influence the format, page count and layout.
Learning objective: You can distinguish between different types of folds and binding methods and select them appropriately based on volume, paper and usage.
Processing begins in the layout.
7.1 / Folding correctly
A fold determines the reading direction.
These are the folding types and techniques you should know:
01
roll fold
The parts are folded in one after the other; the inner part must be slightly narrower.
02
concertina fold
The folds run alternately, like an accordion; all sections are of equal width.
03
Cross-fold
After the first fold, a second one follows crosswise; typical for printed sheets and mailings.
04
Grooves
Creasing indents the fold line; from around 150 gsm, it prevents the fold from cracking.
With a letter fold, the folded-in panel is 2 to 3 mm narrower so that it sits neatly. Folds should run parallel to the grain direction; folding across it makes the paper more likely to crack. For card and coated papers, creasing is therefore essential.
For cardboard: crease first, then fold.
7.2 / The right binding
Scope and usage determine the binding.
Bindings differ in durability, lay-flat behaviour and cost. Saddle stitching with wire staples is quick and economical. Perfect binding produces a square spine and is suitable for higher page counts.
PUR perfect binding is stronger and opens wider than conventional hot-melt adhesive binding. Thread sewing is the most durable: the folded sections are sewn together, and the book lays completely flat.
01
Saddle stitching
Folded sheets are nested inside one another and stitched along the fold; the page count must be divisible by 4.
02
Perfect binding
Pages are milled at the spine and glued; PUR adhesive offers the strongest hold.
03
Thread stitching
Folded signatures are sewn together; highly durable, the book lies flat when open.
The longer in use, the more securely they bind.
7.3 / Select binding
Page count and usage are the deciding factors.
Wire-o binding holds the pages in place using a twin-loop wire spiral inserted through punched holes. The printed item lies completely flat and can be folded back 360 degrees. This makes it ideal for calendars, recipes, and menus.
Saddle stitching works for up to around 64 to 80 pages, depending on the paper, and the page count must be divisible by 4. With thicker booklets, the inner pages creep forward; the printer compensates for this. Perfect binding requires a spine of around 3 mm.
Count the pages first, then bind.
Exercise
Build a dummy
Task: Create two dummies for the "Kornfeld" menu card with different finishes.
STEP 1
Choose the format, number of pages and paper for the menu card.
STEP 2
Make one dummy as a folded product and one as a stapled booklet.
STEP 3
Check the grain direction, fold quality and lay-flat behaviour.
STEP 4
Choose one variant and give reasons for your choice.
Evaluation: Which option holds up better in everyday café life, and why?