When we say "die cut" jacket, what we mean is that a special cutting and scoring fixture (aka: die-cutting fixture) was created to give that particular disc packaging its shape. You can use the word custom to replace die cut if you like. In manufacturing, we use a die to create the packaging. If you want to change any aspect of the packaging (number of pockets, size, shape, little windows, etc.) then a new die is needed to create that. We have done so many variations in our company history that we have an astounding amount of dies already created. But our clients never cease to amaze us with their creativity, so we are still making unique dies on a daily basis.

Disc packaging is often based on some conventional heights. For example, cds tend to go in jewelcase sized packages, or about 5 inch. DVDs tend to go in amaray cases, about 7 inch. Do they have to? No. There are no constraints in manufacturing that push the sizing in this direction, it's just convention. So feel free to play with the sizing and change it around.

Disc packaging is made by printing onto a single sheet of board paper stock (cardboard thickness, usually 15/16pt), and then using a die cutting fixture to cut out and score the flat shape of the packaging. It is then folded and glued to create the final piece that you see. This is what a die fixture looks like:

Die cutting fixture for a double-wall DVD slipcase

When you view your color matchprint, you will see the die lines where the cuts ultimately will be made. It is a great idea to do some folding along those lines to make sure your art is lining up the way you envisioned it.

Here are some examples of the many 4pp jacket/ wallet/bifold type designs we have done. We have an extraordinary number of designs, and we make more all the time. Note that adding a hub or a tray does not affect the basic design at all.

These are great examples of 6pp jackets (trifold) with custom dies. Set yourself free.

This shows a few custom jackets at the standard DVD case height (7 1/2 inches) and bigger: