1. Why Prepress File Configuration Matters
A dieline acts as the architectural blueprint for custom printed packaging cardboards and bags. If vector nodes, bleed areas, or color spacing parameters are incorrectly configured in design files, the physical print can shift, cut off text, or render blurred graphics during manufacturing.
2. The Standard 3-Layer Prepress Setup
When preparing layouts in Adobe Illustrator (AI), structure your document using three distinct, labeled vector layers:
- Layer 1: Dieline (Non-Printing) - Contains cut lines (solid red vector strokes) and fold lines (dashed green vector strokes). This layer directs the laser cutting table and must never be merged with artwork.
- Layer 2: Artwork - Contains your custom logo, text, graphics, and background gradients.
- Layer 3: Technical Notes - Dimensions, print varnishes (matte, gloss, UV spot), and spot Pantone colors pointers.
3. Configuring Bleed & Safe Margins
To compensate for mechanical shifts on high-speed rotary cutting machines, extend your background colors and graphics a minimum of 3mm past the red cut line. This is your bleed area. Likewise, keep all critical text, branding badges, and barcodes at least 3mm inside the cut line. This is the safe zone.