A buyer spends weeks finalizing a display design. The colors are perfect. The branding is on point. The artwork is sent to the factory. Two weeks later, the pre-production sample arrives — and the logo is blurry, the brand color is wrong, and there are white borders around the edges. The problem was not the design. It was the print file.
Proper print file preparation is the single most important step between a design concept and a successful cardboard display. Incorrect file formats, wrong color modes, missing bleeds, and improper resolution are the most common causes of print errors — and they are entirely preventable. A correctly prepared print file ensures that the display looks exactly as the designer intended, with accurate colors, sharp text, and clean edges.
I have spent 16 years receiving artwork files from buyers and designers around the world. I have seen every mistake — from RGB files printing dull colors, to text placed outside the safe zone getting cut off, to images at 72 DPI printing pixelated at full size. This guide covers exactly what you need to know to prepare print-ready artwork for custom cardboard displays, including file formats, color specifications, dieline templates, bleed requirements, and a pre-submission checklist.
Understanding Dieline Templates
A dieline is the technical drawing that shows where a cardboard display is cut, folded, creased, and glued. Every print-ready artwork file must be built on top of an accurate dieline template.
What a Dieline Shows
| Element | Line Type | Appearance | What It Means |
|---|---|---|---|
| Cut line | Solid line | Full line | The display is cut along this line |
| Fold line (score) | Dashed line | - - - - - | The board is creased and folded here |
| Perforation | Dotted line | · · · · · | The board is perforated for tear-away sections |
| Glue tab | Shaded area | Gray fill | Adhesive is applied in this area |
| Bleed edge | Dashed outer line | Extends 3mm beyond cut | Artwork must extend to this line |
| Safety zone | Inner dashed line | 3–5mm inside cut | Keep all content inside this line |
How to Get a Dieline
| Method | Time | Cost | Best For |
|---|---|---|---|
| Request from your supplier | Free | Included | All projects — supplier provides the exact dieline for your display |
| Structural drawing from engineer | 1–3 days | $50–$200 | Complex displays with custom shapes |
| Existing CAD file | Immediate | Free | Repeat orders using the same display structure |
| Manual measurement | High risk | Free | Not recommended — dimensional errors are common |
Critical rule: Never create your own dieline or modify a supplier's dieline without approval. A dieline error of 1mm can cause misalignment on a large display panel, waste materials, and delay production.
File Format Requirements
Accepted File Formats
| Format | Accepted? | Best For | Notes |
|---|---|---|---|
| Adobe Illustrator (.ai) | ✅ Yes | Vector artwork, logos, text | Industry standard; outline fonts before submitting |
| Adobe PDF (.pdf) | ✅ Yes | Final print file (most common) | Ensure PDF/X-1a or PDF/X-4 compliance |
| Adobe Photoshop (.psd) | ⚠️ Conditional | Raster images, photo backgrounds | Must be 300 DPI, CMYK, flattened layers |
| CorelDRAW (.cdr) | ⚠️ Conditional | Vector artwork | Confirm with supplier; may need conversion |
| Encapsulated PostScript (.eps) | ✅ Yes | Vector logos, illustrations | Older format, still widely accepted |
| TIFF (.tif) | ✅ Yes | High-resolution raster images | Must be 300 DPI, CMYK, no compression |
| JPEG (.jpg) | ⚠️ Caution | Reference images only | Lossy compression degrades quality; not recommended for final print |
| PNG (.png) | ❌ No | Web use only | RGB only, no CMYK support, not print-ready |
| Word (.docx) / PowerPoint (.pptx) | ❌ No | Office documents | Not print-ready formats |
File Format Best Practices
| Rule | Why |
|---|---|
| Submit vector formats for logos and text | Vector art scales to any size without pixelation |
| Convert all text to outlines (curves/paths) | Prevents font substitution if the supplier does not have your fonts |
| Embed all linked images | Missing links cause low-resolution placeholders in the final print |
| Flatten all layers in raster files | Prevents accidental layer visibility changes during file handling |
| Use PDF/X-1a or PDF/X-4 standards | These standards guarantee print-ready output with embedded fonts and proper color handling |
Color Specifications for Print
CMYK vs RGB
| Color Mode | Use For | Why |
|---|---|---|
| CMYK (Cyan, Magenta, Yellow, Black) | All print files | Printing presses use CMYK ink — colors reproduce as intended |
| RGB (Red, Green, Blue) | Digital screens only | RGB has a wider color gamut; converting to CMYK shifts colors |
The most common color error: Designs created in RGB look vibrant on screen but print dull and muted in CMYK. Always design in CMYK from the start.
Color Accuracy Guidelines
| Requirement | Specification | Why It Matters |
|---|---|---|
| Color mode | CMYK | Required for all commercial printing |
| Total ink coverage | Maximum 300% (sum of C+M+Y+K) | Higher coverage causes ink smearing and long drying times |
| Black text | 100% K (black only) | Registration black (C+M+Y+K) causes text ghosting |
| Rich black (large areas) | C60 M40 Y40 K100 | Pure 100% K looks washed out in large areas |
| Spot colors (brand colors) | Specify Pantone (PMS) number | Ensures exact brand color reproduction |
| Color proof | Request a digital or physical proof | Confirms color accuracy before production |
CMYK Value Reference for Common Colors
| Color | CMYK Values | Notes |
|---|---|---|
| Rich black | C60 M40 Y40 K100 | Standard for large black panels |
| Process black | C0 M0 Y0 K100 | For text and thin lines only |
| White | C0 M0 Y0 K0 | White is the paper color — not printed |
| Silver metallic | C20 M15 Y15 K0 + PMS silver | Metallic requires spot color or foil |
| Gold metallic | C20 M30 Y60 K0 + PMS gold | Metallic requires spot color or foil |
Digital Color Proofing
| Proof Type | Accuracy | Cost | Turnaround |
|---|---|---|---|
| Screen proof (PDF) | Low — screen dependent | Free | Immediate |
| Calibrated soft proof | Medium — depends on monitor calibration | Free–$50 | 1 hour |
| Digital print proof (inkjet) | Medium-high | $30–$100 | 1–2 days |
| Press proof (on actual stock) | Highest | $100–$300 | 2–5 days |
Recommendation: For brand-critical color, always order a printed proof on the actual display material. Screen proofs show what the file contains, but they cannot show how the ink will look on corrugated board.
Bleed, Trim, and Safe Zone
The Three Zones of Every Panel
| Zone | Definition | Distance from Cut Line | What Goes Here |
|---|---|---|---|
| Bleed area | Extra artwork extending beyond the cut line | 3mm (0.125") outside | Background colors, images, patterns — extends to here |
| Trim line (cut line) | Where the display is cut | 0mm | Cut line itself — no artwork here |
| Safe zone | Area where all important content must stay | 3–5mm inside cut line | Logos, text, barcodes, product images |
Bleed Requirements by Display Type
| Display Type | Recommended Bleed | Why |
|---|---|---|
| Standard corrugated display | 3mm (0.125") | Industry standard; allows for cutting tolerance |
| Large format display (48"+) | 5mm (0.188") | Larger panels have more cutting variation |
| Die-cut complex shape | 3–5mm | Irregular cuts need extra tolerance |
| Litho laminated panel | 3mm | Lamination alignment adds another tolerance layer |
| Counter display (small) | 3mm | Standard bleed for all display sizes |
Safe Zone Guidelines
| Content Type | Minimum Distance from Cut Line | Risk if Closer |
|---|---|---|
| Main logo | 5mm (0.188") | Logo gets partially cut off |
| Text (body) | 3mm (0.125") | Text edges get trimmed |
| Barcode | 5mm (0.188") | Barcode becomes unscannable |
| Product image | 3mm (0.125") | Image looks cropped |
| Pricing information | 5mm (0.188") | Price text unreadable |
| Brand name | 5mm (0.188") | Brand name appears incomplete |
How Bleed Works in Practice
The display is printed on a sheet larger than the final panel size. The excess (bleed area) ensures that when the display is cut, the artwork extends to the edge of the panel without leaving unprinted white borders.
Image Resolution Requirements
Resolution Standards
| Image Type | Required Resolution | Notes |
|---|---|---|
| Photographic images | 300 DPI at final printed size | Standard for all printed displays |
| Product photos | 300 DPI minimum | Lower resolution causes pixelation |
| Logos (vector) | No minimum — scalable | Use .ai or .eps vector files — resolution independent |
| Logos (raster) | 300 DPI at final size | Must be high resolution; do not enlarge raster logos |
| Background textures | 300 DPI at final size | Lower resolution looks blurry in large areas |
| Web-downloaded images | 72 DPI typical | NOT suitable for print — will appear pixelated |
Resolution Calculation
| Step | Formula | Example |
|---|---|---|
| 1 | Determine final print size | 24" wide × 18" tall |
| 2 | Multiply by 300 DPI | 24 × 300 = 7,200 pixels wide |
| 3 | Multiply height by 300 DPI | 18 × 300 = 5,400 pixels tall |
| 4 | Minimum image size required | 7,200 × 5,400 pixels |
Quick reference: A full-page image on a 24" × 18" panel requires a minimum of 7,200 × 5,400 pixel image. Most web images (1,920 × 1,080) are far too small.
Image Quality Warning Signs
| Problem | Likely Cause | Solution |
|---|---|---|
| Image looks fine on screen but blurry when zoomed | 72 DPI web image | Replace with 300 DPI version |
| Jagged edges on curves or text | Low-resolution raster | Convert to vector or increase resolution |
| Color banding in gradients | Insufficient bit depth or JPEG compression | Use 16-bit TIFF or vector gradient |
| White background around logo | Logo saved as JPEG with white box | Use PNG with transparency or vector .ai file |
Typography and Text Guidelines
Font and Text Specifications
| Requirement | Specification | Why |
|---|---|---|
| Minimum font size | 6pt for critical information | Smaller text is unreadable in print |
| Minimum font size (reverse type — white on dark) | 8pt | White letters spread slightly on dark backgrounds, reducing readability |
| Font embedding | Convert all text to outlines (curves) | Prevents font substitution or missing font errors |
| Font licensing | Ensure commercial use license | Some fonts restrict commercial printing use |
| Text to cut line minimum distance | 5mm (0.188") | Prevents text from being trimmed off |
| Multiple text sizes | Hierarchy: headline 48pt+, subhead 24–36pt, body 8–14pt | Creates readable information hierarchy |
Text in Vector vs Raster
| Format | Best For | Why |
|---|---|---|
| Vector text (outlined in .ai or .pdf) | All text, especially small sizes | Prints crisp at any size — always use for body text, fine print, and logos |
| Raster text (as part of a .psd or .tif) | Large display text (headlines) | Acceptable for very large text where pixelation is less noticeable |
Critical rule: Always convert text to outlines/curves before submitting artwork. This prevents font substitution errors that can change your design and cause production delays.
Printing Method File Requirements Comparison
Flexographic Printing
| Requirement | Specification |
|---|---|
| File format | AI or PDF with outlined fonts |
| Color mode | CMYK or spot colors (Pantone) |
| Minimum line weight | 0.5pt (0.007") |
| Minimum font size | 8pt |
| Minimum dot size | 2–3% (highlights may drop out) |
| Registration tolerance | ±1mm |
| Bleed | 3mm minimum |
| Best for | 1–2 color designs, large solid areas, long runs |
Litho Laminated Printing
| Requirement | Specification |
|---|---|
| File format | AI or PDF/X-1a |
| Color mode | CMYK + spot colors |
| Minimum line weight | 0.25pt (0.0035") |
| Minimum font size | 6pt |
| Minimum dot size | 1% |
| Registration tolerance | ±0.3mm |
| Bleed | 3mm minimum |
| Best for | High-quality full-color printing, photo-realistic images |
Digital Printing
| Requirement | Specification |
|---|---|
| File format | PDF or TIFF |
| Color mode | CMYK |
| Minimum line weight | 0.25pt (0.0035") |
| Minimum font size | 6pt |
| Registration tolerance | ±0.2mm |
| Bleed | 3mm minimum |
| Best for | Short runs, variable data, prototypes |
Screen Printing (Spot Colors)
| Requirement | Specification |
|---|---|
| File format | AI or PDF with spot color separations |
| Color mode | Spot colors (Pantone) — one file per color |
| Minimum line weight | 1pt (0.014") |
| Minimum font size | 10pt |
| Registration tolerance | ±1mm |
| Best for | Large solid color areas, simple designs, special inks |
For more on printing methods, see our custom display printing and finishing guide.
Pre-Submission Checklist
File Content Checklist
| # | Check Item | Pass/Fail | Action if Fail |
|---|---|---|---|
| 1 | All text converted to outlines/curves | Convert before submitting | |
| 2 | All images embedded (not linked) | Embed linked images | |
| 3 | Color mode set to CMYK | Convert from RGB | |
| 4 | Dieline template is in a separate locked layer | Separate dieline from artwork | |
| 5 | Total ink coverage under 300% | Reduce ink values | |
| 6 | Images at 300 DPI minimum at final size | Replace low-res images | |
| 7 | Logo and text at least 5mm inside cut line | Move content into safe zone | |
| 8 | Bleed extends 3mm past cut line | Extend background to bleed edge | |
| 9 | Black text set to 100% K only | Change from registration black | |
| 10 | Pantone spot colors specified if required | Add PMS numbers |
Pre-Submission Process
| Step | Action | Who Does It |
|---|---|---|
| 1 | Design artwork using supplier's dieline template | Designer |
| 2 | Convert all text to outlines | Designer |
| 3 | Set color mode to CMYK | Designer |
| 4 | Verify all images are 300 DPI at final size | Designer |
| 5 | Run pre-flight check in Adobe Acrobat or Illustrator | Designer |
| 6 | Export as PDF/X-1a or PDF/X-4 | Designer |
| 7 | Send to supplier for artwork review | Buyer |
| 8 | Supplier checks for technical issues | Supplier |
| 9 | Supplier returns corrected file or requests changes | Supplier |
| 10 | Approve final file for production | Buyer |
Recommended Pre-Flight Tools
| Tool | Cost | Platform | Best For |
|---|---|---|---|
| Adobe Acrobat Pro Preflight | $20.99/month | Desktop | Industry standard — comprehensive PDF checking |
| Adobe Illustrator Preflight | Included with Illustrator | Desktop | Checking .ai files before export |
| PitStop Pro (Enfocus) | $599–$999 | Acrobat plugin | Professional-grade preflight and correction |
| Markzware FlightCheck | $499 | Desktop | Standalone pre-flight for multiple formats |
| Online preflight tools (Zamzar, PDF2Go) | Free–$15 | Web browser | Basic checks for simple files |
Common Artwork Mistakes and How to Fix Them
Top 10 Artwork Errors
| Error | What Happens | How to Fix |
|---|---|---|
| RGB color mode | Colors print dull, dark, or shifted | Convert to CMYK before saving |
| Missing bleed | White edges appear around printed panels | Extend background 3mm past cut line |
| Low-resolution images (72 DPI) | Images print pixelated and blurry | Use 300 DPI images at final size |
| Text not outlined | Supplier missing font = wrong font used | Outline all text before submitting |
| Linked images not embedded | Images appear as low-res placeholders | Embed all images in the PDF |
| Content outside safe zone | Text or logo gets cut off | Move all important content 5mm inside cut |
| Total ink > 300% | Ink smears, long drying time, set-off | Reduce ink values to below 300% |
| Black text as rich black | Text ghosting, registration issues | Use 100% K only for small black text |
| Wrong file format (.jpg, .png) | File rejected by production | Submit AI, PDF/X, or high-res TIFF |
| No dieline layer separation | Dieline prints on the panel — visible after cutting | Place dieline on a separate locked layer, set to overprint |
How to Avoid Each Mistake
| Strategy | Prevents |
|---|---|
| Use supplier-provided templates with locked dieline layers | Wrong dieline, content outside safe zone, missing bleed |
| Set Illustrator or InDesign to CMYK in the new document dialog | RGB color mode |
| Collect all images at 300 DPI before starting the design | Low-resolution images |
| Outline fonts as the final step before saving | Text not outlined |
| Run Acrobat Preflight before submitting | Multiple errors caught at once |
| Request a digital proof from the supplier before production | Color errors, missing content |
For more on the production process, see our cardboard display manufacturing guide.
FAQ
What file format should I use for my display artwork?
PDF/X-1a or PDF/X-4 is the preferred format for most display printing. It embeds fonts, preserves CMYK color data, and includes bleed specifications. Adobe Illustrator (.ai) files are also widely accepted. Avoid JPEG, PNG, or office document formats — they are not print-ready.
What is a dieline and why do I need one?
A dieline is a technical template that shows where the display will be cut, folded, and glued. It is essential for print file preparation because it defines the exact boundaries of each panel. Without a correct dieline, your artwork will not align with the display structure. Always request a dieline from your supplier before creating artwork.
What is the difference between CMYK and RGB?
CMYK (Cyan, Magenta, Yellow, Black) is the color mode used by printing presses. RGB (Red, Green, Blue) is used for screens. RGB has a wider color range, but colors shift when converted to CMYK. Always design in CMYK for print files. Designs created in RGB will print duller and darker than they appear on screen.
How much bleed do I need for a cardboard display?
Standard bleed is 3mm (0.125") beyond the cut line on all sides. This extra artwork ensures that no unprinted white edges appear after cutting. For large format displays (48"+), use 5mm bleed. Never set artwork to stop exactly at the cut line — cutting tolerance means you will get white edges.
What resolution do I need for images on a display?
All images must be 300 DPI (dots per inch) at their final printed size. Web images (72 DPI) are not suitable for print — they will appear pixelated and blurry. A full-panel image on a 24" × 18" display requires a minimum of 7,200 × 5,400 pixel resolution.
Why should I outline fonts in my artwork?
Outlining fonts converts text into vector shapes. This prevents font substitution errors — if the supplier does not have the specific font installed, their system will substitute a different font, which changes your design. Always outline all fonts as the final step before saving your artwork file.
What is the safe zone and why is it important?
The safe zone is the area 3–5mm inside the cut line where all important content (logos, text, barcodes) must be placed. Content placed outside the safe zone may be partially cut off during trimming. Think of the safe zone as the area where you are certain the design will survive the cutting process.
Can I use images from the web on my display?
Not directly. Web images are typically 72 DPI at a small size. Even a high-resolution web image at 1,920 × 1,080 pixels is only 6.4" × 3.6" at 300 DPI. For a 24" display panel, you need a 7,200-pixel-wide image. Source images from professional photography or stock photo services that provide high-resolution downloads.
How do I ensure my brand colors print accurately?
Specify Pantone (PMS) numbers for all brand colors, and request a printed proof before production. Monitor-based color proofs are unreliable. A physical proof printed on the actual display material is the only way to confirm color accuracy. The cost of a proof ($30–$300) is a fraction of a full production run with wrong colors.
Do I need a pre-flight check before submitting artwork?
Yes — a pre-flight check is essential. It scans your file for common errors: missing fonts, RGB images, low resolution, missing bleeds, and ink coverage violations. Adobe Acrobat Pro includes a built-in preflight tool. Running a preflight check takes 5 minutes and can save weeks of production delays.
