The Calendar Cards Get a New Sleeve

When I first made the Useful Calendar (more on that here) into a set of cards, from its original format on a single sheet of letter size cardstock, I fashioned a sleeve to hold them by adapting a template designed for artist trading cards (ATCs). The calendar cards at that time were ATC-size (2.5" x 3.5").

Because it was a flat sleeve with the seam on the side, and I was putting 16 cards in them, I made it a little bigger and gave it some reinforcement by laminating the whole thing with packing tape. It was rather fussy and time-consuming to make each one that way, but it made a very durable, long-lasting sleeve that could be refilled each year for several years.

Then I made the cards slightly larger to make better use of the paper I printed them on. Instead of trading card size (2.5" x 3.5"), I made them 1/8-letter size (2.75" x 4.25"). Now I don't need to trim anything away, I just cut the printed cardstock into 8 cards.

But these no longer fit the old sleeves, so I adapted the sleeve I was using to accommodate the new size. I made a pattern out of stiff plastic upcycled from a pocket folder, so I could just trace around it.

That worked fine for a few years, mostly because I don't do a high volume of business, especially of the pocket version of the calendar (I sell more of the ones with a wood stand aka a desk calendar). But then I had an inquiry last January from a person who wanted to buy a large quantity for their employees, with the sleeves, and I couldn't accommodate them. They settled for 15 of them and let me know at that time that they would like a much larger quantity for Year of the Ox (2021).

So I started looking for a ready-made sleeve that I could use, but could not find anything the right size. Then tinkered with creating a better design that would still be durable while also being easier to make. I noticed that the card sleeves I found online had the seam in the center of the back instead of at the side. I thought that looked nice and would be stronger because there isn't the stress that a seam on the side has to contend with. 

I also realized that I needed to accommodate the thickness of the 16 cards in a more precise way than just making the sleeve a bit bigger. I used a technique similar to the draping method of designing clothing (I used to be a seamstress/tailor), wrapping scrap paper around a rectangle of corrugated cardboard representing a stack of cards, creasing it at each edge, front and back. From this I took measurements and notes.

I then tested some paper samples I had, making a miniature prototype because my samples were so small. I carried the test sleeve in my wallet for several weeks, taking it out and handling it and putting it back to test its durability. It became apparent that the new design would hold up very well.

I made a new template in InDesign so that I could print them with my own artwork on the front (and brand them with my shop name on the back). Then tested the printed one on some nice gray cardstock I already had in letter size (it's set up to print 2 on a letter-size sheet), by handling it a lot and rubbing the printed side with my fingers. As I had feared, the toner started to rub off and look worn, so I coated it, and the others I had made so far, with Gel Medium, a clear acrylic that can be used as a sealant. Because the sleeves were already assembled when I brushed it on, they resisted warping from the moisture in the medium, and it dried pretty quickly. It results in a sheen on one side of the sleeves, and visible brush strokes, but I think of that as just the handmade touch.

Now I need to get in touch with that customer from last January to see if she still wants the Year of the Ox calendars! Even if she doesn't, I appreciate that her inquiry prompted me to design a better card sleeve.