Stock Selection

* Factors to consider in stock selection include surface characteristics, grain, gauge, weight, material density, printing inks or coatings to be applied, and finishing processes to be used.
* Generally, the stocks most receptive to embossing dies are stocks that are uncoated, heavier in weight, and have a felt finish.
* Embossing on heavier stocks will most often provide greater dimensional depth and detail.
* If some of the stock being embossed or hot stamped is thicker in gauge, advise the engraver to "tool" increased depth into the die to give more definition when it is embossed. The greater depth will compensate for thickness, memory, and stock resistance.
* It is desirable to have the die "bottom out" or strike the paper at the point where the stretch of the material comes close to reaching it's maximum limit without cracking or tearing.
* Coated, varnished, or lightweight stocks have a tendency to crack when embossed. Paper and ink have limitations in the degree that they can be stretched before cracking. Coatings cannot be stretched, so care should be taken with any type of embossing on coated or varnished stock.
* Embossing with foil instead of ink can assist to eliminate cracking on coated stocks.
* If heat is applied to the embossed die, such as in foil stamping or glazing, it will increase the chances of the coated and lightweight stock becoming brittle, which may cause the embossing process to crack the stock after the die strikes the material.
* Textured stocks may compete with the embossed image if the texture is too deep. However, for a blind emboss, a slightly textured stock provides the best results.
* Consider the direction of the paper grain when embossing or scoring. Emboss and score in the direction of the grain since going against the grain can cause cracking problems. Occasionally, such as with borders, it is necessary to go against the grain to achieve the desired effect.
* Recycled paper may cause the embossing to be inconsistent in appearance from sheet to sheet, since the higher the content of recycled fibers, the weaker the stock when exposed to heat and pressure. Use paper with 30% post-consumer fiber or less.
* Long-fiber sheets are the best for embossing, since they are capable of handling a wider variety of embossing dies, particularly the deeper dies.
* Sulfate and foils are the best board stocks to be used when embossing packaging materials.

Artwork Preparation

* Set copy or create images with fonts above 12 point and lines thicker than 2 point. Use images that are more open and have fewer thin lines. Embossing will have a tendency to fill in small, enclosed areas, thin lines, or closely kerned text.
* Thin serifs do not emboss well unless they are large and well defined.
* It is generally best to prepare images slightly larger than the size desired. This is to compensate for the resulting dimensional effect that occurs because the paper thickness tends to change the size of the image.
* For greater depth, provide more letter space in the artwork.
* Copy or images with very close registration may involve extra work and greater cost. Be careful not to use trapping techniques on any artwork appearing adjacent to embossing and foil stamping.
* Screened copy and images with changes in tones do not reproduce effectively into dies for embossing, so line art should be created as if it were a solid image or solid color.
* If a beveled die is to be used, the artwork and copy for the image may need to be slightly enlarged to compensate for the image and copy reduction that occurs due to the beveled edges.
* Keep images at least 1/2" away from the edge of the stock being embossed in order to eliminate wrinkles that will occur if the embossed image is too close to the edge of the stock.


Image and Die Preparation

* If film negatives are to be made for the dies, they must be prepared emulsion up.
* If the image has no appearance that easily indicates the direction of the image, mark the film "read right" to show which side prints up. Identify the top or bottom of the image so the engraver will understand how the die must be prepared for proper embossing placement.
* Color key proofs, used for viewing the proper image direction, are of much assistance to the engraver when creating dies.
* If the embossed image is to register with a printed image, make sure the engraver has one of the primary negatives for guidance.
* Make sure the film image is not distorted or altered in size from the original copy.
* If stock is to be embossed and also foil stamped, prepare a separate piece of film or separate digital artwork for each image.
* For multi-level dies (also referred to as sculptured or dimensional dies), an engraver must be provided with a color coded, solid, opaque film for each layer to be embossed. The opaque film identifies the silhouette area of each layer. The engraver must also receive film of the line art that will contain the images to be embossed. Include a set of color keys that will be in register with the film and visually show the intended image.
* As a general practice, make sure the engraver has a color key, a mock-up of the design, and any other samples illustrating and defining the edges, shapes, and levels of the embossed image in order to assist with identifying exactly how the image is to appear when embossed.

Die Selection
Magnesium Dies

* Least expensive of all dies
* Photomechanically etched
* Best for short runs up to 5,000 impressions
* For use on smooth stocks
* Due to softness of die metal, a slight rounding effect may occur

Copper Dies

* Mid range of cost
* Used for runs up to 100,000 impressions
* Used to provide better detail and reproduction of fine lined copy and images

Brass Dies

* Most expensive of the dies to produce
* Created with a manual drawing machine called a pantograph or created entirely by hand
* Used for very long runs, some in excess of 1,000,000 impressions
* Provides the highest quality reproduction giving sharp detail and clean bevels

Die Selection Suggestions

* Refrain from using bevel edge dies when embossing and foil stamping as a combination emboss. The foil will not adhere to the beveled edge.
* Beveled dies are generally made of brass with the edge of the image being sloped 30 to 50 degrees. Do not use magnesium for beveled dies.
* Multi-level sculptured dies work best for scorching and blind embossing.
* Request a proof of the embossing or foil stamping, if possible, to eliminate surprises from possible misconceptions of the appearance of the finished product.
* Consult a die maker or print supplier before making a final image selection for the die. The engraver will know that the clarity and sharpness of the details is one of the most important elements of the foil stamping or embossing.
* Make sure the die maker knows the type of stock on which the die will be used.
* Finer detailed images will be best embossed with a shallow depth. Bold images are best for deeper embossing. The type of stock and the image will determine the depth of the embossing die.

General Use of Embossing

* Logos or accents surrounding logos.
* Borders or highlights surrounding images or information used to attract attention.
* Elegant accents for distinctive symbols, images, graphics, or lines.
* Occasionally used for security in the form of seals or symbols of authenticity on certification for government documents, corporate papers, and official materials. It is considered an older form of security as more alternatives in print and technology have been developed.