How to Create a Dieline That Works for Both Australian and US Retail Markets?

I meet the same problem many brands face. One display must fit two markets. Rework burns time and money. I use one master dieline system and fix it for both.

Build one master dieline in vector CAD, keep dual units (mm and inches), reserve GS1 barcode zones for EAN-13 and UPC-A, map to AU 1165×1165 mm and US 48×40″ pallets, set bleed/safety/score allowances, and validate by a physical prototype.

I sell B2B displays, so I write from the factory floor. I design, test, and ship. My team supports fast samples, free tweaks, and strength tests. I share my field notes below.

How do you create dielines?

I start with where the display will live. I list retailer rules, pallet size, product weight, and barcode type. Then I design to one master.

I define product and retail limits, choose board and flute, set cut and crease layers, keep bleed and safety, plan UPC/EAN zones, palletize for AU and US, build a sample, and stress-test before print.

My step-by-step build

I keep steps simple and visible for my team and for buyers who need speed. I write every value in mm and inches to avoid errors. I also lock barcode quiet zones because US buyers use UPC-A, while many AU buyers use EAN-13. I always palletize early¹. US warehouses expect 48×40″ footprints, while Australian DCs often plan 1165×1165 mm (CHEP). I keep both maps in the master file, and I tag them. I also plan strength from the start. Hunting gear and outdoor tools add weight, so I add larger glue flaps and wider feet on floor displays. I test with drop and vibe tests² because transport hurts weak feet first. I run a quick digital print sample to confirm color and text sizes for older shoppers. I do a small run to confirm assembly time on the shop floor. I keep the dieline clean, so the store staff reads it in seconds.

What are the guidelines for dieline?

I write rules before I draw. Rules save hours later. I set clear layers, safe areas, and label needs for both markets.

Use clear layer names, dual units, 3–5 mm bleed, 5–8 mm safety, barcode quiet zones, flute/grain notes, pallet maps, glue zones, and assembly arrows; validate with a sample and a drop test.

Cross-market rules I rely on

I keep guidelines that my designers and press crews can follow with no guesswork. I keep bleed at 3–5 mm, and I increase to 6 mm on heavy corrugated where registration drift is higher. I mark safety at 5–8 mm from cuts and 10 mm from crash-lock bottoms. I note flute direction to support vertical load. I keep the barcode area unprinted⁵ for the quiet zone. I write both UPC-A and EAN-13 options into the art board, so the brand chooses late without a re-draw. I add pallet and aisle constraints, because US warehouse aisles and AU DCs handle different turns and stack patterns. I add simple assembly arrows; store staff must build fast. I include recycling marks⁶ that fit each market policy when requested. I check color with a low-cost digital proof. I run a one-unit transit test for corners and feet. I sign off only after the prototype passes.

What is a dieline structure?

A dieline is not only a shape. It is a set of layers. Layers tell knives, creasers, printers, and packers what to do.

A dieline structure is a layered file that separates cut, crease, perforation, glue, print, and notes, so design, tooling, and production read the same plan without guesswork.

Layers that never fail me

I keep strict colors and line types. Cut lines stay as solid magenta and overprint off in art proofs. Crease lines use dashed cyan. Perforations use dot-dash. Glue zones use a soft tint fill. Print-only graphics live on their own layer and never touch the tooling layers. I add an assembly layer with arrows and numbers for store staff. I include a compliance layer⁹ with empty panels for ARL or other recycling marks in AU and for US retail notes. I keep a palletization layer¹⁰ with outlines for both markets. I lock a measurements layer with dual units. I include a notes layer for board grade and finish, like E flute, single-wall, and matte AQ varnish. This structure speeds handoff. Prepress can trap art without moving cut paths. Tooling can export DXF for the die maker. Production can check glue positions at a glance.

What is the difference between template and dieline?

People mix these words. That causes costly mistakes. I keep them separate in my files and in my talks with buyers.

A template is a starting layout for fit and brand; a dieline is the final, tool-ready, layered path set for cutting, creasing, and glue. Templates guide; dielines manufacture.

How I explain it to teams and buyers

I use template¹³s in early talks. A template shows outer size, rough panels, and where key art might sit. I use it to collect feedback and to speed design sign-off. A template is flexible and fast. I never send a template to a die maker. A dieline¹⁴ is different. A dieline is precise and locked. It has cut, crease, perf, and glue layers. It includes barcode zones, pallet maps, and notes. It is tool-ready. I move from template to dieline only after the brand approves the 3D render and the sample. I learned this the hard way on a heavy floor display for an outdoor line. I rushed a template to tooling. The feet tore in transit because there was no extra score allowance. I rebuilt with a true dieline, added bigger feet and different flute direction, and the display passed drop tests. Since then, I keep the names clear in emails, file names, and quotes.

Conclusion

One master dieline, two markets. I design with dual units, barcode options, pallet maps, and strict layers. I prototype early. I protect time, cost, and trust.