Custom Digipaks Packaging & Replication


Die Cuts, Special Printing Effects & Paper Stocks

Custom Digipaks with Die Cut Window Showcasing Booklet

We can create a die cut for the Digipak Packaging that creates a special shape or cut out window or letters. In this case, the window in the front panel is showcasing the booklet front & back images.

For more info on Die Cuts, check out: Custom Die Cuts 

Custom Digipaks die cut packaging digipak with window showcasing booklet image

Cuppola’s Secret

4pp Tall DVD Digipak (7inch height)  with Die Cut Window
Booklet in Front Tube Panel
Printing 4C/4C + spot uv gloss &  matte lamination

Spot UV Gloss and Matte Lamination

Spot UV gloss ink is beautifully contrasted with a matte lamination and you can do some gorgeous artistic effects with it.

Check out our page on this printing effect for more examples: Spot Gloss

Fiberboard Paper Stock

Fiberboard Paper is unbleached, pulp material that is recycled and used rather than discarded. It has a beautiful nubby texture and organic quality. If you want “true color” as if printed on white paper, special white ink is required.

See Also Fiberboard

special printing effects silver foil fiberboard stock


4pp CD Digipak (5inch height)
Recycled Fiberboard Paper
Soy Ink 4C/4C
Silver Foil Stamping
Booklet (uncoated recycled stock) in tube pocket

Foil Stamping makes for Fantastic Custom Digipaks

Foil Stamping imparts a shiny foil imprint on the packaging. It can be somewhat intricate and is available in many colors such as Gold, Silver, Red, Blue, Teal, and Multicolor Reflection Colors.

For more examples see: Foil Stamping

Wide Digipaks - Turn it Sideways to make a Custom Digipak

If you turn the tray sideways, you have what is called a Wide, WideScreen, Landscape or Horizontal Digipak. This is much more common with 7inch trays. It can be done with 5inch trays also which are not exactly square.
Wide Digipak custom digipak with tray turned sideways, landscape


4pp Wide Digipak (7inch tray)
4C/4C Printing + Spot Gloss & Matte Lamination
Hidden Pocket under Tray

Type of Trays in Digipaks

  • 5inch clear plastic (allows art to be seen underneath)
  • 5inch solid black or white (special order)
  • 5inch paper (100% recycled/cork hub)
  • 7inch tall single disc, clear plastic
  • 7inch tall double disc trayNote – 10inch Digipaks can be made by combining two 5inch trays on a very tall panel

Custom Digipaks : X, Plus or Cross Digipak Configurations

Cross or Plus Shaped Digipaks can be made and these are generally 10pp to 14pp number of panels. The center panel can be a little tricky on these with trying to fold up the digipak so it is usually best to place a booklet or pocket there.
Cross shape Custom Digipaks Multidisc Set 4discs plus booklet


Number of Panels in Digipaks

4pp = 4 panels (2 inside, 2 outside), like a bi-fold
6pp = 6 panel (3inside, 3 outside), like a trifold
8pp = 8 panels (4 inside, 4 outside)
10pp = 10 panels gatefold, or plus/cross shaped with 5 unique panels inside /outside
12pp = 12 panels gatefold, or plus/cross shaped with 6 unique panels inside /outside
14pp = 14 panels gatefold, or plus/cross shaped with 7 unique panels inside /outside

Custom Digipaks with Business Cards

A great way to customize a Digipak is with a business card. We frequently put these in slots in a diagonal literature panel. We have also made die cut windows that showcase the name on the business card.
DVD Digipak business card spot gloss embossing


4pp Tall Digipak
Diagonal Literature Pocket with Business Card Slot
Printing 4C/4C + spot gloss & matte lamination, embossing on cards
Set of 5 titles run together: Digipak, DVD, Booklet, Business Card
Customization of Names on  Business Cards and on Digipak Spines

Adding Business Cards, Return Envelopes, and Other Items

We can make business cards with all kinds of paper stock and special effects printing to match the main Digipak. We can also do things like return address printed envelopes (rsvp, business reply, mailer), staggered literature, and pretty much any other add on item you can think of.

The business cards in this title used a Spot Gloss and an Embossing Effect.

Matte Digipaks

There are a few ways we can make a matte digipak for you. The choice is often dependent on the artwork. An uncoated paper is absorbent so the ink will spread a bit. For crisper art, it is better to use coated stock and seal it with a lightweight varnish, or heat apply a matte lamination layer.

  • Uncoated white stock paper – 1side uncoated or both sides uncoated depending on density desired
  • White Coated paper with a matte varnish or matte lamination
  • Fiberboard stock (also uncoated)
Uncoated digipak matte


4pp Digipak
Uncoated Stock with Soy Inks, 4C/4C
Diagonal Pocket Inside
Folded Poster, also Uncoated Stock

Tips for making a Vintage, Retro Look Custom Digipak

  • Uncoated stock is one of our favorite tips for a vintage feel. The texture is soft (ie maybe a little older, maybe used?) and the colors are slightly muted.
  • Soy inks help with this effect too.
  • Distressed art – put some defects in your artwork, make the paper have some tears or burns, add a book binding effect or consider making an actual book .
  • 4C/4C Printing – whatever you do, don’t forget to carry the impression across the entire product. White glaring spines gives it aways.
  • Paper Trays look more retro than plastic, yes?
  • Fiberboard stock has a wonderful vintage look, especially with the strongly muted colors.
  • Fabrics like linen or cloth, or material like vinyl leatherette are very fun too.
  • Cream colored booklet pages can be specially ordered, or better yet, use that background color in your art.
  • Kraft Paper has a wonderful vintage feel
  • Don’t hesitate to use an extra thick stock or construction method to make it sturdy.

Custom Digipaks Made with Foam Trays - USB Digipaks

Foam trays can be made to hold discs and USBs, or items like pencils or coins. They can be made in any shape or dimension.

For USB Models we manufacture, check out our USB Page and our Custom USB Packaging Page

USB packaging tall jacket foam tray 2 dongles


4pp Tall Digipak with Diagonal Literature Pocket
Custom Foam Tray to hold Disc & 2 USB Dongles
Printing on Digipak 4C/4C
Discs Serialization, printed with unique product key

Black Foam or Printed Paper Wrapped Foam

If you’re not keen on the solid black foam, we can apply a 4C printed wrap to the foam. We do this frequently on Digipaks that have an odd number of trays, but need the space balance out. A printed foam filler tray does the trick!

Multi Disc Mega Tall Digipaks - 10 Inch Height

MegaTall Digipaks made made by using two 5inch trays on one very tall panel…the result, a 10inch high Digipak. It is a great way to put multiple discs in one package and the height is impressive. If you need it to fold up to a neat portfolio, we can do that!
If you have an odd number of discs, we can use a printed foam filler tray to replace the missing tray.

See Also Multidisc Sets

Custom Digipak DVD set with 3 paper trays, 10inch height digipak, curved pocket, magnet flap, coin die cut hole organic packaging

Living Battlefield

8pp MegaTall Digipak – 6pp regular width panels, 1 partial “flap” panel
10inch Height Tall Digipak – 3 paper trays + 1 Printed foam filler tray
4C/4C Printed Fiberstock Paper
Die Cut Curved Literature Pocket
Folded Poster Uncoated Paper
Die Cut Hole for Collector Coin
Magnets in Flap

Custom Digipaks with Paper Trays - 100% Recycled Paper, Cork Hub

If you haven’t seen paper trays yet, you are in for a treat. These are very eco friendly (100% Recycled paper with a cork hub inside the tray) and fun to design with.  They go beautifully with fiberboard stock and uncoated paper.

Visit our Custom Digipak Photo Gallery


ESI Custom Packaging, Media Manufacturing

OBI Strips, Belly Bands, Stickers, Ribbons, Magnets, and Velcro Tab Fasteners

The Bells & Whistles Page of Fastener Add-ons We love to make custom projects and because we have creative clients (hint – you should be one of them), we have a large portfolio of really fun add-ons we can show...

Slipcase Sets Slipcase Boxes- Multidisc CD DVD Set, Vinyl, Books

Slipcase Sets – Bundles CDs or DVDs Discs, Multidisc Set Packaging, Vinyl Records, Books We manufacture custom Slipcase Sets to fit whatever is in your set. For example you may have discs in digipaks, or a paper book set, or...

Kraft Paper Disc Sleeves, Inner Wraps for Hardcover Books

Kraft Paper Disc Sleeves, Box Packaging and Book Linings Kraft paper is popular for creating disc sleeves, either glued-on or swinging. Glued on – adhered to inside panels of books or a jacket. Swinging sleeves – moveable, they flip like...

Reusable Fasteners, Custom Closures

Reusable fasteners / custom closures not only look cool, but they help you keep the contents intact in your package. Adding Strings, Ribbons, Magnets and Velcro Tabs to CD DVD Vinyl & Video Screen Packaging: Strings, Ribbons and  Ties can...

Spot Gloss Ink and Matte Lamination Contrast on Printed Packaging

Spot Gloss with Matte Lamination Printing on Packaging Spot UV Gloss is a special ink that can be applied to packaging and cured under special UV lights. The result is a very shiny patch of clear ink. A subtler spot...

Uncoated Matte Paper CD DVD Packaging Soft, Vintage Look

Uncoated Matte Paper CD DVD Packaging Perfect for Vintage or Watercolor Art Uncoated paper is unvarnished / unfinished. It does not have the normal aqueous topcoat that most sealed and finished papers have. The paper stock is soft to the...

Perfect Bound Book, Saddle Stitch, Hard Cover, Soft Cover, Spiral Notebooks

Perfect Bound Book vs Saddle Stitch Binding  A Perfect Bound Book refers to both the binding and trimming. Perfect Binding is where the pages and booklet cover are glued together at the spine with a very strong glue. The pages...

Foil Stamping on Printed Packaging, CD DVD USB Video

Hot Foil Stamping on Printed Packaging Hot foil stamping is a process that imparts a shiny, reflective imprint onto printed packaging. Common colors are silver, gold, red, blue, and copper, but we have a whole palette to choose from…in fact...

Embossing / Debossing on Printed Packaging CD DVD USB Video

Embossing / Debossing on Printed Packaging Embossing is raised relief. Debossing means indented. These effects can be done on any type of cardboard packaging such as LPs, Digipaks,  Box Sets, and more. It is not uncommon to see embossing on lettering, and...

Organic Packaging – Fiberboard, Unbleached, Recycled, Uncoated

Organic Packaging – Fiberboard, Uncoated, Recycled, Fabric Hemp Organic Packaging options for any type of media, including box sets, jackets, folders, digipaks, and more Non plastic alternatives including 100% recycled paper trays with cork hubs,  foam hubs, glued on sleeves...