A 3D render might look flawless on a screen, but the physical world answers to the laws of caliper thickness and fold displacement. Here is how master packaging designers prepare production dielines that fold impeccably every single time.
Accounting for Paperboard Caliper in Folds
When heavy paperboard folds 90 or 180 degrees, the material inside compresses while the outer face stretches. Adding 1.5x paper thickness to dust flaps ensures seamless closures without bulging.
