Perforation creates a line of small cuts in paper or card that allows a section to be torn away cleanly by hand. It is a functional finishing process used on reply cards, tickets, vouchers and any printed piece with a detachable section. We produce perforation in-house at our Marrickville finishing department.
What is perforation
Perforation uses a serrated blade or rule to create a line of evenly spaced cuts and ties (uncut bridges) through paper or card. The cuts weaken the material along the line so it tears cleanly when pulled. The ties hold the sections together until the tear is intended.
The ratio of cut to tie determines the tear behaviour. A higher cut ratio makes the tear easier. A lower cut ratio holds the sections together more firmly during handling and mailing.
When to use perforation
Perforation is used wherever a printed piece needs a detachable section. Common applications include reply cards on direct mail pieces, event tickets, raffle tickets, voucher books, tear-off forms, order pads, invoice books and RSVP cards attached to invitations.
It is also used on packaging to create easy-open tear strips and on shelf-ready displays to create break-apart sections.
Perforation methods
We produce perforation using three methods. Rotary perforation on the press perforates during the print or folding pass. Steel rule perforation uses a perforating rule set into a die, applied during the die-cutting pass. Offline perforation uses a standalone perforating unit for jobs that do not go through a die.
The method is selected based on the job construction. If the piece is already being die-cut, the perforation rule is built into the die at no additional tooling cost.
Design considerations
Position the perforation line at least 10mm from any fold to prevent tearing during folding. Allow at least 5mm clearance from the perforation line to any critical text or image that should not be interrupted by the cut marks.
Perforation works on paper and card stocks. Very thick board (above approximately 400gsm) may not tear cleanly and may require a different cut-to-tie ratio.
How we produce perforation
The perforation method is determined during job planning. For die-cut jobs, the perforation rule is incorporated into the die. For standalone perforation, the sheet is fed through our perforating unit after printing and before any binding or assembly.
We test the tear quality before production to confirm the perforation performs as intended on the specified stock.
Need a tear-off section on your next direct mail, ticket or form project? Get in touch to discuss perforation.
Frequently Asked Questions
Can perforation be combined with die-cutting?
Yes. The perforation rule is set into the same die as the cut and crease lines. Both are applied in a single press pass.
How close to the edge can a perforation line be?
We recommend at least 5mm from any trimmed edge to prevent the perforation from weakening the sheet during handling.
Can I perforate thick card?
Card up to approximately 400gsm perforates cleanly. Heavier stocks may need a modified cut-to-tie ratio. We test before production.
Is perforation visible on the printed surface?
Yes. The cut marks are visible as a dotted line on the surface. The position should be incorporated into the design so it appears intentional.
Can perforation lines be curved?
Straight perforation is standard. Curved or shaped perforation is possible using a custom die but adds complexity and cost.