The Studio On Fire Letterpress Calendar is a favorite project in our shop for nearly ten years. It’s been worked on by many contributors from all over the world. Each year Studio On Fire puts together a loose theme, color palette and paper choices, then we invite 5 other designers / illustrators to participate. We design 2 months, and each contributor designs 2 months. Its always nice to have a large cross section of stylistic approaches within a little package that sits on your desktop. And this year is no exception. 2011 participants include Studio On Fire Adam Garcia, Brian Gunderson, Jessica Hische, We Make It So, and Aesthetic Apparatus.

This years calendar is a departure from the usual graphic illustration in our previous versions. Our theme this year was “Letter Form Genus”, with many contributors incorporating type and lettering. We’ve not had a distinctly type related theme before, so this was extra fun. Some favorite details you’ll find are: a moustache wearing a monocle, a spider wearing a thong, a monkey skull on a snake skeleton, a hidden giraffe, and bacterial letter forms spelling “grow kindness.”

The calendar is printed all together on a large 26 x 20 size press sheet. It is trimmed down into 12 months on 3.25 x 5 inch cards. This year, the paper for the months and the outer wrap was a light brown Wausau Winter Wheat 100lb Cover. We design the tri fold outer wrap using bits and pieces of each months design, all mashed together and printed in a long strip.

The stand was a custom duplexed paper made from dark grey Fibermark Eviva Stone 100lbC and copper Stardream 111lbC paper stocks. Our easel stand design has a clever fold-out angled leg that reveals the inner metallic paper color. The grey stock is letterpress printed in one color metallic silver.

These are now available on our studio site.

We’ve been doing this calendar for almost ten years now and have been fortunate to have some really great people involved. See a couple previous years here: 2010 Calendar, 2009 Calendar, 2008 Calendar.

We letterpress printed them with 2 colors – a copper metallic ink and a tonal white ink. We used Wausau Royal Complements Bright White 100lb Cover paper stock. The card press sheets were printed then pasted together with an extra sheet in the middle to produced a triplexed sheet for an extra thick custom 300lb cover stock. They were trimmed and finished with the metallic edge color. These are lux with a definite presence.

For the production, we hand fed them on our Chandler and Price letterpress. We used a small block of deep relief Boxcar base in an unusual way. Instead of using photopolymer plates, we used a 16 gauge copper plate mounted with double stick tape adheisive. We used copper rather than polymer in this case so we could be a little more aggressive with the impression on the wood. To accomodate the thickness of the tongue depressor, we had to back the platen off a few flats. Then, since the artwork is so tight to the edge the big challenge was fitting the guides pins EXTREMELY tight to the print area and not crush them. But it worked! We printed a couple hundred on both sides. A real challenge to hand fed, press was on a pretty low speed setting. Not something we’d like to do everyday, but we are suckers for trying things that are unique. But we did have Matt open all the individually packaged depressors.

Also, take a look at our Chandler and Price hand guard. It is a window-shade-like device that opens up as the press closes and pushes your hand out of harms way. Kind of a nice safety feature.

(These are some of my first iphone pictures, so forgive the quality.)

Designer Aya Ikegaya created this beautiful invitation structure for a wedding in Tuscany, Italy. We produced this by combining letterpress printing with blind embossing. The outer sleeve is actually the invitation. Inside is a thick cotton card letterpress printed with maps and details. The sleeve, envelope and tag are all blind embossed with crisply beautiful typography.

We often see letterpress printing confused with embossing. It is two very different processes, yet can be completed on some of the same equipment. Blind EMBOSSING raises the type and requires a much more expensive 2 part copper die with a fiberglass counter. Conversely, the letterpress printing on the interior map card uses less expensive photopolymer plates. We’ve included some photos showing these production materials side by side to illustrate the difference. We use a heated chase on our Heidelberg Windmill for this type of work. With heat applied to the copper plate, the type is much more crisp. After the embossing, the sheet was custom die cut and converted to sleeves. Because of the time and materials involved, custom work of this nature is more costly than a standard letterpress printed project. But the effect is amazingly simple elegance.