Printing and Laminating Instructions

Paper type:

• Don't use cardstock (60 lb paper). The lamination will peel once you cut the cards unless you cut the cards first and then laminate them. Way more work! I wouldn't go more than 32 lb. If you do, try laminating and cutting one sheet first to see if rough handling will cause peeling. It's a good idea to do a test run all the way through the process with one page to make sure. 
• Standard printing paper (20 lb) is see-through when resting on a surface. I ended up using 32 lb paper, but I think 28 lb paper would do the job as well.

Printing Tips:

• Use a color laser printer, it's much cheaper. Perhaps a friends has one they will let you use.
• To prevent smearing on the sides, first choose the correct paper type in Adobe Acrobat. Go to print --> properties --> paper and tray --> paper type. Then choose an option that slows down the color printer: thicker paper, cover, coated, etc. Your options will change depending on your printer.
  • Important tip when using a color laser printer: print in small batches to prevent overheating which may cause smearing on the edges. Examine each batch when it comes out to prevent misprints.
• In Adobe Acrobat print options, choose "Actual Size" instead of "Fit" to get cards that are 2 inches square. Regardless, make sure the same option is clicked with both the front and back files if printing them separately to keep the back images aligned with the front images. 

Laminating Tips:

• Place the picture in the 3 mil pouch and close it. (I didn't use a 5 mil pouch, I don't know if the thicker plastic will be more likely to peel once cut. You will have to run a trial to check that.) Examine the page and then remove any sand, hair, etc, that could get laminated into the cards. 

• Turn on the laminating machine and let it warm up. A light will tell you when it's ready. Make sure it is set to 3 mil if you are using 3 mil to ensure the proper operating temperature.
  • Tip! The laminating sheet will not feed all the way through the machine. Once it stalls on the last inch, you gently pull it out to prevent an overheating line.

Cutting and Box Assembly:

• I ended up using scissors instead of a paper cutter since I wasn't confident I could do perfect cuts every time with the paper cutter. Definitely the most tedious part. 
• Tip! To prevent random laminated cards from sliding out the bottom of the boxes, I used blank mailing labels to close that small slit off once I assembled the box. Regular scotch tape would work too, but the white labels matched the box and last longer. (Just picture a container full of 30 little boxes, and 5 random cards have fallen out the bottoms of the boxes. I really didn't want to have to go through 30 boxes and figure out which cards went where!)