Custom Booklet Printing

There is no minimum page count. We can print anything from a single page up to 100 pages or more, and booklets rarely go beyond 2,000 pages. Tell us your page count and we will recommend the binding that suits it best.

Saddle stitching uses metal staples through the center fold. It is economical, lies flat, and suits rulebooks of 8 to 64 pages in multiples of four. Sewn binding uses thread to secure the folded sections, giving extra strength and a booklet that opens flat on the table, which suits thicker or frequently used rulebooks. Perfect binding glues the pages into a squared spine that can carry a printed title, and it suits booklets of about 40 pages or more.

Most instruction booklets use 80–120 gsm text paper for the inner pages, which reads well without making the booklet too thick. Covers commonly use 200–300 gsm art paper for extra stiffness and durability. Matte or gloss lamination, soft-touch lamination, foil stamping, or spot UV can be added to the cover for a more durable or premium finish.

Common sizes are 2.5 × 3.5 in (63.5 × 88.9 mm) for tuck boxes, 5 × 7 in or 5.5 × 8.5 in for small two-piece boxes, 6 × 9 in or 8 × 8 in for standard 10 × 10 in boxes, and 8.5 × 11 in or 8.5 × 8.5 in for large boxes. Most of our orders are made in custom sizes, so send us your box dimensions and we will size the booklet to fit.

Yes. The cover and inner pages are usually different papers, and you can even use several paper types inside one instruction booklet, for example coated pages for illustrations and uncoated pages for text or notes.

Send one print-ready PDF with fonts embedded, in CMYK, with 3 mm (0.125 in) bleed on all edges and images at 300 dpi. Put all pages in order in a single file, with the cover first. For saddle-stitched booklets, the total page count should be a multiple of four. Booklet templates are available on request.

It depends on the quantity and our production schedule. EzraCard typically completes bulk booklet print orders within 1–4 working days, and proof printing is usually finished within a week.

Yes. We regularly collate, insert, assemble, and pack booklets together with cards, accessories, inserts, and other components. Complete sets can be packed in tuck boxes, rigid boxes, drawer boxes, or display packaging, and each set is checked for the correct booklet version, component count, and packaging placement before shipment.

Folded leaflets and cross-fold sheets are usually the most practical formats for short instructions, safety information, quick-start guides, and multilingual content. They are compact, lightweight, and economical, and can fit inside small tuck boxes or rigid card boxes without requiring a separate bound booklet.