Setting Up Embossing Plates
When we tried to set up embossing plates for the first time, it felt like someone had handed us instructions in a foreign language. If you’ve ever read a vendor email and thought, “This seems like English, but I don’t understand a word of it,” we’re here to say—you’re not alone.
This post breaks the process down, from Adobe Illustrator setup to press alignment. If you’ve already listened to the episode and want a visual or written walkthrough, this is for you.
Embossing vs. Debossing
Let’s start with the most basic confusion we see on the client side: embossing means raised design, and debossing means pressed-in. Embossing is achieved using two plates—a male and a female—that press your paper between them to form the raised shape. This is the opposite of the deep impressions most clients associate with letterpress.
Understanding Male and Female Plates
To create an emboss, you need both a male and female plate:
The male plate pushes the shape from the back of the paper.
The female plate sits on the front side and captures the raised impression.
Most embossing mistakes happen during file prep because the artwork isn’t properly mirrored or spaced. The plates have to fit perfectly together—with a gap the same thickness as your paper.
Before You Start: Know Your Paper’s Caliper
You need to know the caliper (thickness) of the paper before setting up your plate files. This is usually measured in points (1 point = 0.001 inches), and has nothing to do with font size or Illustrator stroke weight.
To find caliper:
Use a micrometer or calipers to measure the paper.
Or check the manufacturer’s spec sheet (e.g., Colorplan’s 91 lb text = 8 pt caliper).
This caliper measurement is what determines the spacing between your male and female plate shapes.
Key Illustrator Terms To Know
Path: A vector shape in Illustrator (like a letter or logo).
Closed Path: A shape that has no open ends (i.e., outlines of letters).
Stroke: The outline weight applied to a path.
Choke: Reducing a shape’s path or stroke to create space.
Spread: Expanding a shape’s path or stroke to make it larger.
You’ll use choke to reduce part of your design so that there’s a precise gap between the two plates equal to the paper’s thickness.
File Setup: Step-by-Step
Start with Your Design
Pick a letter or shape (e.g., a “K” or something asymmetrical is a good test option)
Convert it to outlines (a closed path)
Set it to the final size (e.g., 2 inches tall)
Create Your Male Plate
Keep the original artwork and mirror it.
This is counterintuitive, but because the vendor will flip it back, it must be mirrored in your file.
Create Your Female Plate
Duplicate the artwork and place it inside a square or base shape (e.g., a 4x4 inch box).
Use the Pathfinder tool > Divide to cut the letter out of the square.
Ungroup and remove the letter, leaving a knockout.
Create a Visual Gap
You’ll now create a small space between the male and female shapes to match your paper’s thickness.
In Illustrator, stroke the inside of both shapes with white.
A typical rule: 0.75 pt total choke (split as 0.375 pt on each shape) works well for 8 pt paper.
Use the stroke alignment tool to apply strokes to the inside of each shape.
Use a Line to Represent Paper Thickness
Draw a bright-colored line (green or blue) with a stroke width equal to your paper caliper (e.g., 0.008 in).
Place it between the male and female shapes to visually check your spacing.
Un-Mirror Your Female Plate
Once both plates are spaced, flip the female artwork back to right-reading.
This step is crucial. Your plates will face each other in the press, so they must be mirrored relative to one another.
Submitting to Your Plate Vendor
Save each plate as a separate vector-based PDF with clear labels (e.g., "Male_Emboss_K.pdf" and "Female_Emboss_K.pdf"). Include a note with the paper caliper and confirm the plates are for embossing—not foil or deboss.
Most vendors (like Concord Engraving) are happy to check your file if you're unsure.
On Press: Registering and Packing
Once your plates arrive, here’s a quick overview of setup:
Mount Your Male Plate on your base.
Align the Female Plate using blue tape and your male plate as a guide.
Close the Press Gently to transfer alignment.
Build Up Packing under the female plate (not over it).
Cut small pieces of packing material and place only behind the embossing area.
Avoid overlapping edges of the plate.
Your paper will feed face down, with the design being pushed from the back and captured by the female plate on top.
Test and Adjust
The first time you try this, consider ordering 2–3 female plates with slightly different gaps (e.g., 0.006", 0.008", 0.010"). It’s a small investment that helps you dial in the perfect pressure without cracking your stock.
Once you find a setup that works, save those measurements! They’ll become your go-to for future embossing projects on similar paper.
Final Words
Embossing can feel intimidating at first—but once you understand the math, the mirroring, and the Illustrator tricks, it’s surprisingly satisfying. We promise you’ll be hooked the first time you hold up a crisp, raised monogram and run your fingers across the surface.
Now let’s make that cheat sheet!