5.5 Punchboard | v.20210625

A punchboard is an incredible versatile component that can be utilized to create a multitude of items such as tokens, tiles, trackers, and dials. It can be single layer, dual layer, or even fit together to create a constructible cardboard component. As a result the punchboard is one of the most difficult print components to create. In addition to following all of the regular rules relating to any print piece, please be careful when planning the token layout, and pay attention to special dieline, bleed, and margin requirements.

5.5.1 Punchboard size

To comfortably fit in the box, the size of the punchboard should be at least 15mm smaller in each dimension than the box top. 

Example: a 200mm x 250mm box can hold a punchboard of 185mm x 235mm

5.5.2 Individual Token Sizing 

The smallest token size LongPack can produce is approximately 8mm x 8mm, and the smallest edge in any unique shape must be at least 3mm long.

5.5.3 Dieline spacing 

1. There should always be a minimum of 6mm between any dielines, either token to token, or to ken to whole board dieline. 

2. Each individual punch out (token) on the punchboards should have 3mm of bleed outside its dieline. 

3. 3mm (at least 2.5mm) of margin between the dieline and any non-background art including text and border lines.

5.5.4 Dieline file 

Please save your dielines as a separate PDF file, or as a separate layer in your art file. Dielines can not be part of the regular art file layers, they need to be separate so that a diecut mold can be created. 

5.5.5 Label and number your punchboards 

It is very important to mark and number the diecut mold, in case you have designs sharing the same diecut mold or diecut molds with similar dielines, so that they can be easily identified. With marks/numbers on molds, it will prevent mixing mistakes from happening in the process. Marks and numbers can be added outside the dielines, which will be discarded in final assembling and packaging. 

Please find mark/number on a diecut mold circled in Red in the example to the right. 

5.5.6 Back side layout 

Ensure that the layout of the back sheet of the punchboard artwork is a mirror image of the front of the punchboard. You can see an example of this to the right. 

5.5.7 Shared dielines (cost saving) 

Think about efficiency when designing punchboards, as there is added cost for each diecut mold. You can lay out your punchboard in such a way that the same dieline template can be used for multiple punchboards. 

The dieline template on the right will be more efficient.

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