PRODUCTION NOTES
Challenge 1: Precise Dimensional Calibration for Custom Slipcase Enclosure
The Challenge
Constructing a rigid protective slipcase using 2.5mm grayboard for a 22mm thick volume requires exact geometric tolerances. Excess clearance allows the volume to shift during transit, while overly tight dimensions risk abrading the cover artwork upon insertion.
Our Solution
Utilized precision V-grooving technology on the 2.5mm grayboard and lined the inner walls with 100g offset paper to create seamless 90-degree internal edges. Calibrated dimensional allowances during pre-production trial fitting to guarantee a precise, smooth sliding fit.
Challenge 2: Preventing Surface Wear on Full-Bleed Dark Outer Coatings
The Challenge
Both the hardcover wrap and slipcase artwork feature high-density dark printed graphics, which are highly susceptible to scuff marks, scratches, and friction damage during automated casing-in and handling.
Our Solution
Applied a specialized anti-scratch matt lamination over all outer sheets prior to board mounting. Enforced strict interleave paper placement between finished sets to maintain flawless surface integrity throughout packing and sea freight.
Challenge 3: Tonal Consistency Across Separate Substrates and Finishing Runs
The Challenge
Maintaining matching color densities and shadow depth between the hardcover paper wrap (mounted on 3.0mm board) and the slipcase wrap (mounted on 2.5mm board) across independent lamination and assembly cycles.
Our Solution
Conducted pre-press lamination proofing tests and established strict inline densitometer checks against approved target proofs. Synchronized press parameters across both components to ensure uniform tonal reproduction.