Paper Folding Options for Brochures, Maps and Book Inserts

Paper folding options determine how a flat printed sheet closes, opens and reveals its content. The selected structure affects panel widths, reading order, paper choice, scoring and the final folded size.

These folds are used for brochures, maps, instruction sheets, promotional inserts and selected fold-out pages. They are different from the folded signatures that form the page block of a bound book.

Compare the Main Folding Structures

Straight and Parallel Folds

Bi-Fold

A bi-fold, also called a half-fold, uses one fold to create four printable faces. A centred fold gives both sections the same finished width, while an off-centre fold can create a short front flap or stepped edge.

This structure provides a wide uninterrupted spread after one opening action. It suits content with a clear cover, one main interior presentation and a back panel, without requiring the reader to follow several folding steps.

A bi-fold remains one continuous sheet. A multi-page piece joined by staples, adhesive or another binding method should instead be planned as booklet printing.

Tri-Fold and Roll Fold

A letter-style tri-fold uses two parallel folds. One side panel folds inward and the opposite panel closes over it, so the inner panel must be slightly narrower than the two outer panels.

Its width must follow the supplied production template rather than one equal third of the flat sheet.

A roll fold extends the same inward-nesting principle across four or more panels. Each panel moving toward the centre becomes progressively narrower rather than dividing the sheet into equal sections.

It is useful when information needs to appear in a controlled sequence, but the closed edge becomes thicker as more layers are added.

Z-Fold and Accordion Fold

A Z-fold also uses two parallel folds, but the folds move in opposite directions. Viewed from the edge, the sheet forms a Z shape.

Because no panel is enclosed inside another, the three panels are normally the same width.

An accordion fold repeats this alternating pattern across four or more panels. The complete sheet can open into one long surface, making it suitable for maps, timelines, comparison charts and instructions that need both panel-by-panel reading and a continuous overview.

Gate Fold

A gate fold has two outer panels that open from the centre. When fully opened, the two gate panels reveal a centre area approximately twice the width of either closed front panel.

On a 400 mm flat sheet, the basic division is 100 + 200 + 100 mm. The approved production dieline must include the required closing clearance, so the two gate panel widths should not be adjusted independently from that template.

The structure suits a cover image divided at the centre and a wide illustration, product range or comparison revealed inside.

Gatefolds can also add width to printed catalogs when a diagram, panoramic image or product table does not fit a normal page.

If the folded gate is then folded once more through the centre, the result is a closed gate or double gate fold. A gatefold attached inside a bound publication also needs an attachment panel in addition to its visible sections.

Double Parallel Fold

A double parallel fold is made by folding the sheet in half and then folding it in half again in the same direction. It reduces the sheet to one quarter of its original width and creates eight printable faces when both sides are used.

The panels enclosed by the second fold need slightly more clearance than the outer-facing panels. This format holds more information than a tri-fold while remaining compact, but it does not open in the alternating sequence of an accordion fold.

Right-Angle and Combination Folds

French Fold and Cross Fold

A French fold is formed by folding a sheet in half and then folding it again at a right angle to the first fold. It is also called a cross fold, right-angle fold or quarter fold because the closed piece is one quarter of the open sheet size.

This structure works well when the fully opened side carries a poster, map or large graphic. It should not be confused with French flaps, which are extensions of a softcover that fold behind the front and back covers.

The two folds run in perpendicular directions, so the paper grain cannot run parallel to both. The grain should favour the longer or more demanding fold; on heavier stock, the cross-grain fold must be scored and checked on the folded sample.

Map Fold

Map fold is a functional description rather than one fixed folding sequence. A large sheet may first use accordion folds to reduce its width and then a cross fold to reduce its height.

Other maps use a different combination according to the open size and required closed format.

For this reason, “map fold” alone is not a complete production specification. A numbered folding diagram should show the panel order, first and second folding directions, front panel and final closed orientation.

Panel Widths and Production Conditions

Start with the Finished and Flat Sizes

The finished size describes the closed piece, while the flat size describes the complete sheet before folding.

For nested structures, the flat width is the sum of the actual compensated panel widths, not the finished width multiplied by the number of panels.

The approved dieline should identify the front panel and the order of all inside and outside sections. Artwork guides must follow those measurements; the fold lines should not be created by dividing every layout into equal columns.

Match the Paper to the Fold Count

For standard brochure sizes, 128–157 gsm paper is a practical starting range for tri-fold and Z-fold pieces. A map or long accordion fold with several layers is normally easier to open and refold at 105–128 gsm.

Simple bi-fold and gate-fold structures can use heavier paper when properly scored. A nested fold should not default to 250 gsm because the accumulated layers can make the closed piece bulky and resistant.

The brochure paper guide covers paper surface, caliper and fold performance in more detail.

Allow for Grain, Scoring and Lamination

Paper folds more cleanly when the grain runs parallel to the main fold. Folding heavier or coated paper across the grain increases resistance and can leave a rough or cracked edge.

Scoring is normally required for heavier paper, solid ink coverage and laminated sheets. Lamination protects the printed surface but also adds stiffness, so the score must be tested with the selected paper and film rather than specified separately.

Confirm the Finished Fold

Before sampling, confirm the flat size, closed size, fold sequence, opening direction, front panel, paper and surface finish.

For roll folds and non-standard combinations, the structure name should be supported by a numbered diagram showing which panel moves first and which side remains visible when closed.

A physical folded sample confirms panel clearance, edge alignment, reading order and whether the finished piece stays closed without springing open.

Once one of these paper folding options is approved, the same dieline and folding sequence should be retained for the print files and bulk production.