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In roll fold projects, each panel should be sized increasingly smaller for a compact finished product. |
Even “basic” folds can need proper planning to result in attractive finished products. Consider roll folds, which are also called over-and-over or barrel folds. This type of fold is popular for self-mailers, brochures and instructions sheets — products where space is highly valued.
The main layout challenge with roll folded projects is to make sure each panel is properly sized. In a roll folding sequence, each panel is turned over the next one. This requires each panel to be progressively undersized as the piece is opened toward the interior. This is done to compensate for the collective bulk of the “rolled” panels. Here are some tips for calculating panel sizes for roll folding:
Sizing: How Much?
For starters, on all stock weights the outer two panels should be final size. When dealing with text-weight stock decrease each succeeding interior panel by 3/32”. The last panel will be the smallest; make this panel 1/16” smaller than the preceding one. On ultra-light text stock, such as .003, it is generally accepted that decreasing each panel by 1/16” is sufficient, as opposed to the 3/32”. For projects on cover-weight stock, each panel should decrease by 1/8” as opposed to 3/32” for text-weight stock.
Be careful with your calculations. Errors are easy to make when calculating panel sizes. If necessary, ask your bindery for assistance.
Thickness
The most efficient method for creating a roll fold is on a buckle folder. Therefore, thickness will eventually come into play, because the product will become too rigid, failing to make it through the folder’s rollers. As many of you know, a roll fold is achieved by deflecting or bypassing a fold plate. When dealing with cover stocks and multiple panels, the sheer bulk of the product creates a piece so thick it simply won't bend anymore — at this point the folder jams. When in doubt, get back to basics and make a sample.
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At Rickard, we can perform up to 8 roll folds in line with
other production capabilities, such as gluing. |
Design Dangers
A common folding design is to fold a piece once or twice and then roll fold at right angle. It has been our experience that the maximum thickness for this design should be in the .004 neighborhood. Heavier stocks can result in either wrinkling or tearing, or both. Here’s what happens. The roll fold, performed after initial fold(s), actually forces the paper back onto itself. This causes an unreasonable amount of stress at the fold points. With no way for the tension to be released, the paper bursts or wrinkles at the folds perpendicular to the roll.
The Rickard Advantage
Rickard Bindery is constantly pushing to achieve the most complex folding requests. While many binderies stop at 4 or 5 roll folds, we are able to make 8 roll folds and we can even spot glue the piece closed to boot. This gives you more flexibility in terms of design options. At Rickard, we are folding experts. Let us help you layout your roll folding project, calculate panel sizes, and select proper stock for efficient, trouble-free production.
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