How'd They Do That?
In order to provide adequate support to prevent crushing and collapsing, the Samsung box required foam support, which framed the inner well and extended to the outer edges of the box. After a white comp was completed for the design, the next stage in the process was creating flat-die layouts, which we e-mailed to 1Roof. Laying out the art to a die drawing for a dimensional project can be a bit confusing at first, so we provided the designers with a great deal of support and coaching during the layout phase. From a design standpoint, it also is crucial to consider critical issues such as color crossovers on components from different parts of the sheet and the grain direction of the paper, which is key for the proper functioning of the mechanisms.
Production and Fulfillment
After 1Roof's Samsung art was sent to our FTP site and our prepress department QC'd the files, we output low-resolution proofs of the pieces, assembled them and sent them back to Roof. This was the first time the marketer had a chance to see the mailer in three dimensions and check the positioning of the art. After this proof was approved, flat proofs were sent for final color approval.
Perhaps an obvious point is that dimensional projects generally are more complex and have more steps than "flat" projects. For this reason, we recommend that marketers doing a dimensional piece demand singular accountability: one party taking responsibility for the whole production process. Otherwise, if something goes wrong, you can find yourself immersed in a sea of finger-pointing.
The Samsung mailers were hand assembled in our plants in Mexico, which are staffed with highly skilled, full-time workers. Marketers should make sure dimensional mail companies have experience in dealing with the materials and process of complex finishing.