We show you how to generate, print, and build a Panel Poster. If you need more help, check out the support forum or send us your question.

A Panel Poster is an image printed across multiple sheets of card stock and folded into panels measuring about 6.5 x 8.5 x 1/2 inches (16.5 x 21.6 x 1.27 cm). This allows you to produce large, custom posters at a fraction of the cost. The raised panel design gives the poster a professional appearance, is simple to install with our non-permanent, double-stick foam blocks, and panels can easily be replaced as needed.

With a little practice, you can build a panel in less than 2 minutes.

Panel Poster Packs
Scoring, assembly, and mounting materials.
$2.95 - $14.95.

Back to Top

Build Steps

• Video: How to build a Panel Poster
• Step 1: Get Parts, Tools, and Materials
• Step 2: Generate Poster File
• Step 3: Print
• Step 4: Score
• Step 5: Cut
• Step 6: Fold
• Step 7: Assemble
• Resource - Adobe Reader
• Resource - Build Guide (pdf)

Be aware that safety is your responsibility. Please read our Safety Warning and Disclaimer before you start.

Video: How to Build a Panel Poster

Here's a 5:56 minute video showing how to build a panel.

Step 1: Get Parts, Tools, and Materials

For Printing

For Building

PIC 1-1

PIC 1-2

Step 2: Generate Poster File

To make a file for a Panel Poster, we need to pass an image through an application that will enlarge and dice it up across multiple pages contained in a single PDF document. We've covered 4 free applications that do this nicely. Our preference is PosteRazor since it has the ability to create huge, detailed posters using large image sizes.

Choose one of the following for advice on image size and generating your Panel Poster file:

• Generate a Panel Poster File Using PosteRazor
• Generate a Panel Poster File Using Block Posters
• Generate a Panel Poster File Using Rasterbator
• Generate a Panel Poster File Using Rasterbator Standalone

PIC 2-1

PIC 2-2

Step 3: Print

Panel Poster images need to be printed on heavy card stock leaving at least a 3/4” (1.9 cm) margin around each image. This allows room to fold the artwork into a raised panel.

Printing on Macintosh or Windows

1. Load the card stock.
   Load the card stock into your printer as directed by your printer’s manufacturer.
2. Open your PDF.
3. Print dialog settings.
   Click on the “File” menu and choose “Print”. On Mac, set the range for a single page. If you used PosteRazor, leave the scale at 100%. Otherwise, set the scale to 80%.(PIC 3-1, PIC 3-2) On Windows, set the range for a single page. If you used PosteRazor, "Page Scaling" in the "Page Handling" section should be set to "none". Otherwise, set “Page Scaling” to “Tile all pages”, and set “Tile Scale” to 80%. (PIC 3-3, PIC 3-4).
4. Print test page.
   Measure each margin to make sure you have at least 3/4”. (PIC 3-5) They do not have to be equal. Go back to step (4) and modify the “Scale” if you need more/less of a margin.
5. Print poster.
   Once you have the margins verified, set the “Pages” option in the print dialog to “All” and print.

Using a Print Service Provider

1. Prepare USB thumb drive.
   Copy your PDF file to your USB thumb drive.
2. Bring materials.
   Bring your ruler, thumb drive, and card stock to the print service provider.
3. Instructions for the print service provider.
   Tell the print service provider you would like to print on your card stock, and you need a proof of one of the pages before printing the entire file. If you did not use PosteRazor, ask them to scale the file 80%.
4. Check test page.
   Review the print quality and measure each margin to make sure you have at least 3/4”. (PIC 3-5) They do not have to be equal. Go back to (3) and have the print service provider modify the scale if you need more/less of a margin.
5. Print poster.
   Once you have the margins and quality verified, have the print service provider print the entire file while you go out and get a cappuccino. Make sure to check the final output when you are done. Print service providers will usually adjust color and reprint at no charge if you are dissatisfied with the output.

PIC 3-1

PIC 3-2

PIC 3-3

PIC 3-4

PIC 3-5

Step 4: Score

The key to a perfect panel is using our Score Guide to produce properly spaced cut and fold patterns. (PIC 4-1, PIC 4-2, PIC 4-3)

PIC 4-1

PIC 4-2

PIC 4-3

Before you start, here's a few tips to keep in mind.

PIC 4-4

PIC 4-5

PIC 4-6

PIC 4-7

PIC 4-8

PIC 4-9

1. Position score guide.
   Place a page on the cutting mat, face up. Position inside of score guide along picture edge. (PIC 4-10) Hold guide firmly.
2. Score inside edge.
   Using the back edge of a hobby knife, drag a score line along the inside of the score guide while holding the score guide firmly in place with your other hand. (PIC 4-11) Keep the knife at a sharp angle and apply pressure during the process. (PIC 4-12)
3. Score outside edge.
   Score with back edge of hobby knife along the outside edge of guide. (PIC 4-13)
4. Rotate mat and repeat.
   Rotate the mat to the next edge and repeat process. (PIC 4-14) Continue until all 4 edges have been scored. (PIC 4-15)
5. Repeat for other pages.
   Repeat these steps for the rest of the pages.

PIC 4-10

PIC 4-11

PIC 4-12

PIC 4-13

PIC 4-14

PIC 4-15

Step 5: Cut

We need to cut the page corners to create tabs and prevent the back edge from touching when folded. (PIC 5-1) Tabs are left attached to the short side of the page. (PIC 5-2)

PIC 5-1

PIC 5-2

1. Cut score lines A & B
   Cut lines "A" and "B", stopping at line "D". (PIC 5-3, PIC 5-4) Repeat for all four corners.
2. Cut score lines C & D
   Cut line "C", stopping at line "A". (PIC 5-5) Cut line "D" stopping at line "B". (PIC 5-6) Repeat for all four corners.
3. Cut corners
   Cut the corners on the outer score lines at about a 45 degree angle (it doesn't have to be perfect). (PIC 5-7) Repeat for all four corners. (PIC 5-8)
4. Repeat for other pages
   Repeat these steps for the rest of the pages.

PIC 5-3

PIC 5-4

PIC 5-5

PIC 5-6

PIC 5-7

PIC 5-8

Step 6: Fold

Before we can assemble the panel we need to bend, fold, and crease all the score lines. (PIC 6-1)

PIC 6-1

Flip the page over. Grab along the inner score line and carefully bend inwards. Fold and crease the edge. (PIC 6-2, PIC 6-3, PIC 6-4) Repeat for the outer score line. (PIC 6-5, PIC 6-6) Repeat for the all sides. Bend all tabs inward. (PIC 6-7)

PIC 6-2

PIC 6-3

PIC 6-4

PIC 6-5

PIC 6-6

PIC 6-7

Step 7: Assemble

Final assembly is fast and clean using double-stick tape strips. (PIC 7-1, PIC 7-2)

PIC 7-1

PIC 7-2

1. Apply tape strips
   Using the hobby knife and score guide, cut the double-stick tape strips in half. (PIC 7-3) Remove a tape strip from the sheet. Apply the strip at the corners of the inner score line on the long side. (PIC 7-4) Repeat for all 4 corners.
2. Bond the corners
   Carefully remove all the protective sheets from the pieces of tape leaving the thin sticky residue behind (tweezers help). (PIC 7-5) Line up a corner so that the long and short sides are even. The tab should be on the inside. Apply pressure to the tab against the tape to set the corner. (PIC 7-6) Repeat for all 4 corners.
3. Bend outer edge inward
   Grab the outer edge and carefully bend inwards. Fold and crease to force the outer edge to bend inward a little. (PIC 7-7) Repeat for all 4 corners. Flip your panel over. It should sit flat on the table surface. (PIC 7-8)
4. Repeat for the other pages
   Repeat for the rest of the panels. (PIC 7-9) When you are finished the Panel Poster Using Guide will show you how to install your awesome poster.

PIC 7-3

PIC 7-4

PIC 7-5

PIC 7-6

PIC 7-7

PIC 7-8

PIC 7-9