Die-Cutting and Folding: Brochure Folds, Custom Shapes and What to Plan For

By Rajesh Company · November 2026 · 6 min read

A flat printed sheet becomes a brochure, a folder, a carton or a shaped sticker through folding and cutting. These steps look simple at the end, but they decide how the artwork should be set up. Knowing the basics helps your designer avoid files that look fine flat and fail once folded.

Illustration of a tri-fold layout with fold lines next to a custom die-cut tag shape with a cut path

Common brochure folds

Half fold: one fold, four panels. Simple and clear.
Letter fold (tri fold): two folds, six panels. The usual choice for service and product brochures.
Z fold: panels fold in opposite directions, so the sheet opens like an accordion.
Gate fold: two outer panels fold in to meet in the middle, giving a dramatic reveal.
Roll fold: panels roll inward one over another, with the innermost panel slightly narrower.

See brochures and our brochure printing guide.

Scoring and creasing

Heavier paper cracks along a fold if it is folded cold. A crease or score line pressed into the sheet first lets the board bend cleanly. This matters for covers, folders and cartons. Ask for creasing whenever paper is thicker than about a standard flyer stock.

In your artwork, avoid running solid dark colour across a fold line. Even with creasing, a small white line can appear at the edge of the fold.

Die-cutting and custom shapes

A die is a metal blade shaped to cut a specific outline. It can cut rounded corners, windows, pockets, tags, labels, stickers and carton blanks. Because the die is made for the job, the shape is repeatable across a run.

Supply the outline as a separate vector path on its own layer.
Keep bleed beyond the cut line, as with any trimmed piece.
Avoid very sharp internal corners and very thin cut out parts, which can tear.
For stickers, tell us the material and whether you want a kiss cut that leaves the backing intact or a cut all the way through.

See die-cut stickers.

Folders and pockets

Presentation folders combine a die cut shape, creasing and often a pocket with a business card slit. The flat layout is more complicated than the finished folder, so we normally supply a template once we know the size and board. See folders.

Planning ahead

Ask for a template before the design starts.
Remember that panels on the inner side of a fold are usually a little narrower so they tuck in.
Make a paper mock up by hand. It exposes panel order mistakes in a few minutes.
Confirm that finishing such as foil or lamination suits the fold lines.

Talk to Us

Our die-cutting and folding page covers the process in more detail. Combine shapes with surface treatments by reading our finishing guide.

Send details to +91 99101 48075 on WhatsApp or use the quote form on our homepage. Timelines depend on the product, quantity and finishing, and are confirmed when we quote.

Related products: Brochures · Folders · Die-cut stickers