Whether the project involves printed films, large-format graphics, or standard printed materials, clean print data is the foundation for high-quality results and a smooth production process. In practice, we regularly encounter obstacles—both minor and major—many of which are easily avoided if you know what to look out for.
With this article, we aim to provide guidance and a practical reference—compact and easy to understand. The following tips help you avoid common pitfalls when preparing print files, ensuring that design and production work together seamlessly and your project is executed as efficiently as possible.
1. Missing bleed
A common mistake that is easily avoided is the omission of bleed. Many print products require a bleed of at least 5 mm on all sides. If this is not included, visible white edges may appear during final trimming—especially with full-bleed areas or background colors.
Equally important: maintain a safety margin. Ideally, text, logos, or other important content should be positioned at least 3 mm away from the edge to ensure a clean result.
2. Insufficient resolution
An image resolution that is too low directly affects print quality—especially for large-format designs. To ensure images appear sharp and clear from the intended viewing distance, we recommend the following guidelines for resolution at actual size:
150 dpi for close viewing (less than 50 cm)
120 dpi for viewing distances up to 1 m
100 dpi for viewing distances up to 2 m
70 dpi from a distance of 2 m
These specifications serve as a guide; the appropriate resolution may vary slightly depending on the subject matter and material. We would be happy to provide individual advice on the optimal preparation.
3. Incorrect color mode
A common reason for unexpected color results in printing is the use of the wrong color mode. While screens operate using the extensive RGB color space, professional printing relies on the significantly more limited CMYK color space. Colors that appear bold and vibrant in RGB cannot always be reproduced exactly in print.
For reliable color reproduction, we therefore recommend creating print files exclusively in CMYK mode—ideally using the ISO Coated v2 color profile. This effectively prevents color deviations later on.
4. Unclear or incorrect contour lines
For free-form cutouts—such as stickers, labels, or special shapes—a clearly defined cut contour is essential. This should be created as a closed path in 100% magenta (1 pt)—ideally as a spot color named "CutContour"—and placed on the file's top layer.
Important: Please do not enable transparency or overprint effects, as this can lead to incorrect cut data. As always, it is better to ask one question too many than one too few—we are happy to assist with any queries at any time.
5. Incorrectly set up spot colors
Special applications such as white ink, varnish, or primer require specific technical preparation to ensure they are correctly executed during printing. The crucial factor here is:
Create each application as a separate layer.
Use a solid color with a clear designation.
Set to "Overprint"
Example naming and color values for our production:
White: Solid color “white”, 99% cyan
Lacquer: solid color “lack”, 99% yellow
Primer: solid color “primer”, 50% yellow
We know this sounds technical at first glance—but we are, of course, happy to assist with any questions and help prepare the file correctly.
6. Incorrect file formats or incompatible PDF versions
To ensure the data can be processed further without issues, we require a technically sound file structure. The ideal format is:
PDF/X-3 (Version 1.3) – without transparencies, crop marks, or registration marks.
Please do not send:
Open layout files (e.g., InDesign, Word)
Exotic or archival formats such as PDF/A or JPEG 2000
If you are unsure, it is best to simply ask—we would be happy to check in advance whether the format is suitable for production.
7. Excessively intricate elements in plots and adhesive vinyls
The more intricate the design, the more precise the planning needs to be. Plotters and materials have technical limitations that should be taken into account:
Printed films with laminate: Minimum line thickness of 5 mm
Plotter films (e.g., Oracal 751C): Minimum line width of 1 mm
Finer lines may tear during weeding or peel off later. We are happy to advise on the design implementation to ensure the final result remains attractive and durable in the long term.
8. Content too close to folds, creases, or drill holes
Maintaining sufficient distance from the design is crucial—especially for folds, routings, or drill holes—to preserve readability and the visual design. Our recommendations:
Minimum clearance of 5 mm from milled edges
Minimum clearance of 3 mm between drill holes (smallest diameter)
Here, too, the rule applies: the more complex the product, the more advisable it is to coordinate beforehand.
9. Production notes in the margin area
Comments or requests such as "please add more margin on the left" included within the actual print file can easily lead to printing errors—especially in automated production processes. Please always communicate production instructions separately, for example via email or in a clearly named accompanying file.
10. Unclear naming & lack of structure
A clear file structure helps ensure a smooth process. Please note:
Name files unambiguously, e.g., Motif_A_Front.pdf
Send only one file per design.
Clearly mark preview files as such.
This makes assignment easier – especially with multiple products or variants.
11. Misunderstandings regarding multi-part products
Large-format prints often need to be divided into individual segments. It is important to note that slight, technically unavoidable misalignments at the joining edges cannot be completely eliminated. Therefore, avoid the following:
Placing fine details or text over panel joints
Placing important elements directly at segment boundaries
We would be happy to assist with the appropriate layout or handle it directly for you if required.
12. Spelling and layout errors
Please note that we do not check the content of your data. Text, design, and layout are your responsibility.
Should you wish to have the content reviewed or corrected, we are happy to offer this service upon request and for an additional fee.
Conclusion
This overview aims to help avoid common pitfalls when preparing print data—not as a criticism, but as practical support for smooth collaboration. After all, we share a common goal: a technically flawless, high-quality result.
If you are unsure about specific points or have individual questions, please feel free to contact us at an early stage—we would be happy to provide personal, solution-oriented advice.
👉 Further information & PDF Data Sheet
