One important aspect of our discussions about how 6d6 can become a stable business by the end of next year is our production costs. I’ll be writing in details about this tomorrow but first I thought I would show you the process of making them.
The board used for the covers needs to be cut down to size.
I’m using self-adhesive art board which is higher quality than I really need but simplifies the production process.
The end result is enough A5 boards for 16 covers .
The art for the covers needs to be printed and a fixed to the cover.
This is where the self-adhesive art board comes into its own. Unlike glue it doesn’t soak into the paper or become lumpy and it is easier to work with than spray-on adhesives. The pages for the book also need to be printed at this stage.
The covers need to be punched and then eyelets added.
The eyelets give the cover extra strength around the binder rings and prevents tearing. Before this happens, the cover is wrapped in a clear sticky backed plastic for make it more resilient and give a matt finish.
The finished booked with binder rings.
Once the covers are finished, the pages are punched and everything assembled. The black strap is a piece of elastic I was experimenting as a book mark / clasp. It was only used in this prototype and not the final product because it ripped too easily but it is something I would love to add to the books.
Cutting the cards.
Outbreak! comes with about 240 cards. These are printed ten per A4 page and then cut with this handy machine.
The cards are then sorted.
The cards for each character plus the Game Leader’s cards need to be sorted into separated piles with all the cards orientated in the same direction ahead of being punched. This can be a time consuming business.
The cards punched and on binder rings, along with the book are now placed in the packaging (like this).
Producing these covers by hand for the 200+ books we need to sell in 2012 is not viable. The process is slow, expensive and the quality lower than is really acceptable for a broad audience. One of the objects is to find a printer who can produce either the books or just the covers or just the cards or, if I’m lucky, everything.