NOTES FROM THE WORKBENCH
Why cardstock cracks at a fold
A damaged fold can come from the material or the way it is scored and bent. Diagnose it on scrap before changing the net.
Reviewed October 27, 2026
Look at what has cracked
Inspect whether the damage is in the paper fibres, a printed surface or a coating. Check which side was bent outward and whether the crease was scored. A white split in a dark printed coating may be especially visible without meaning that every dimension is wrong.
The generator defines a fold location; it cannot determine scoring pressure, grain direction or the surface treatment of a sheet from its colour or GSM.
Change one thing in a small trial
Use a scrap from the same stock and mark two comparable folds. Try a controlled score with a suitable blunt scoring tool, then bend gently along it. Compare the result with a different orientation on the sheet if you are investigating grain direction.
Keep the scoring surface, tool and amount of pressure as consistent as you can. Pressing harder at random makes it difficult to tell which change helped and can cut or weaken the sheet.
Follow the material guidance
Supplier instructions for the particular cardstock can explain recommended scoring and fold direction. A general tip may help you start, but a coated, laminated or unusually thick sheet can behave differently.
Curved pillow-box folds add another challenge because their direction changes along the arc. Test the curve in scrap before committing the complete blank. Do not replace it with a straight crease merely to make the first attempt easier.
Choose a workable stock and process
If the trial still cracks, reconsider the paper, scoring method or construction. A deeper score is not automatically the right answer. Keep the net's geometric dimensions separate from the practical method used to bend the material.
Record the result and repeat the successful process on a fresh small sample. These steps help you evaluate your stock; the illustrations on FoldParcel are not evidence that a specific paper has been physically tested.
Sources and methods
Ready to make something?
Set the dimensions. Check the folds. Make a small test box.