Before retiring in 2024, Dean Bott, Thysse’s President, took one last walk through our Oregon, Wisconsin headquarters—a space he helped shape during his nine-year tenure with the company and more than fifty years in the printing industry.

Dean was known for giving the best tours in the building. For guests who truly loved the craft of printing, those tours could stretch for hours—filled with stories, insights, and small details that revealed just how much he cared about this work and the people behind it.

When Dean announced his retirement, we couldn’t let him leave without capturing one of those tours in video form. This series preserves his knowledge and perspective—a lasting look at the people, processes, and principles that make Thysse: Where You Go With Your Brand®—from the perspective of a true print expert.

Every brand relies on consistent, high-quality messaging to drive awareness, build equity, and drive growth. Commercial printing is about reproducing those messages, colors and overall brand experience in physical form. There’s a lot more to it than putting ink on paper, at Thysse.

Commercial printing is often described as “custom manufacturing”. Unlike most types of manufacturing where industrial equipment, teams and workflows are aligned to produce the same thing at scale, commercial print is a different animal. Variable substrates, graphics, exact colors, page counts, trims, folds and bindings change and feed into a truly dynamic manufacturing environment. 

In this clip, Dean walks through Thysse’s digital toner, high-speed inkjet, and offset printing. These complement Thysse’s wide format technologies, which extend the same color control to signage, display graphics, and environmental branding. Together, these platforms allow Thysse to reproduce color accurately across every substrate, device and asset type produced here.

Dean often emphasized that technology should support creativity—not the other way around. Thysse’s digital toner presses enable short-run printing and variable-data personalization with remarkable efficiency and quality.

Speed and personalization are key to today’s most effective marketing programs. In this video, Dean showcases Thysse’s HP PageWide A2200 roll-fed inkjet press, a powerhouse for high-speed, variable-data printing and direct mail.

Offset printing remains the benchmark for long-run quality and brand consistency. Dean takes us inside Thysse’s Heidelberg six-color press, where automation, LED-UV curing, and G7 color management work together to deliver exceptional results for high-end collateral and packaging.

Printing is only half the story—what happens next transforms it into something memorable. Inside Thysse’s bindery and finishing department, Dean explains how flat press sheets become beautifully finished materials through cutting, folding, die cutting, gluing, and stitching.

Once printed, every mail piece must be assembled and verified with absolute accuracy. Here, Dean demonstrates Thysse’s camera-based inserting systems and USPS mailing services, ensuring each envelope and insert set is perfectly matched and ready for delivery.

In Thysse’s wide format printing division, ideas scale up and come to life. From retail signage and event graphics to architectural and environmental branding, Dean showcases how Thysse produces large-scale visuals with exceptional detail and color accuracy.

Not every printed piece ships the day it’s produced. Many move through Thysse’s print fulfillment center, where logistics, technology, and inventory management converge. Dean highlights how custom-built Brand Portals give clients real-time control over their printed assets, promotional items, and signage kits—all stored and shipped directly from Dane County to locations nationwide.

The tour concludes with Thysse’s commitment to sustainability. For Dean, sustainability isn’t a buzzword—it’s built into how Thysse operates. From solar-powered printing to renewable paper sourcing and right-sized packaging, sustainability shapes every stage of production.

As Dean steps into retirement, his legacy remains visible in every part of Thysse—from the technology and processes he helped refine to the culture of craftsmanship he championed.

Dean’s tour wasn’t just a farewell—it was a way to preserve the knowledge and spirit that shaped Thysse’s culture.

His legacy lives on in the team that carries that spirit forward—continuing to innovate, explore new technologies, and push the edge of what’s possible. Every day, Thysse looks for new ways to create value, elevate brands, and deliver outcomes that move our clients—and our craft—forward.

So every year, we send out a holiday card. This isn’t an original idea, I’m sure you receive a couple holiday cards every season. But when you think back to last year‘s haul... is there one card that still stands out?

Well, this year, Thysse‘s goal was to be that card. To be the most beautiful and unique card to land on our clients’ desks. Every company has probably had this same goal at some point. Whether for a holiday card, a direct mail piece, product packaging or even an in-store retail experience. You wanted to create something that people would remember, something people picked out from the group, something that delivered that ‘wow’ factor and sparked conversation.

For the holiday card, we kicked things off like we always do—sketching, pulling together mood boards, throwing around ideas as a team. We explored color, texture, format and then settled on a concept that felt timeless, elegant, and just… next level.  

There are a few aspects that really played a role in elevating this year’s holiday card. To start, this card isn’t just something pretty to look at, although we’ll talk about that in a second. It’s designed to unfold like a story as you open it, like stepping into a warm, happy memory that invites you to resonate with the design.

The couple ice skating on the front of the card is a nod to one of my personal favorite winter activities, and I’m sure a favorite for many others as well. I also infused a little company personality, or Thysseness as we like to call it, by featuring an illustration of our headquarters behind the skaters. This helps to bring Thysse intothe scene and adds a branded touch. 

I chose a unique duplex paper for the card. Duplex means it comes black on one side and white on the other. This duplex stock allowed for a rich, elevated black exterior while still allowing for those bright pops of color on the inside. It’s not a stock you come across often, and the quality of the paper is something you notice the second you pick it up.

Now, let’s talk about the finishes that really make this card stand out. I designed a custom diecut window that reveals part of the inside of the card from the front to complete the snow globe look. It adds dimensionality and gives the card that one-of-a-kind look you just can’t replicate.

Instead of using a standard deep yellow gold for the illustration of the snow globe base, I chose a metallic gold ink. It not only elevates it, but printed over the black paper, it gives this faded, nostalgic, almost vintage feel.

I selected two different foils to fill in the rest of the illustration: a shiny silver foil featuring a frost pattern for the ice, and an iridescent opal foil for the snow. The opal foil is used again inside the card to create the effect of falling snow, visible through the die-cut, like a snow globe that’s just been shaken.

Finally, I chose to emboss the “Happy Holidays” text and the ‘Thysse’ nameplate to give the warm message and our company name prominence while adding to the overall tactile and dimensional experience.  

Every decision, from design to materials, was about creating an unforgettable, tactile experience. And then, we brought it to life right here at Thysse. Everything was produced in-house from printing, foiling, embossing, die-cutting and folding. This gave us full control over every last detail and the quality of the finished piece, which is something that really matters when you’re working with specialty finishes.

When the final cards came off the press, they looked… show-stopping. It was exactly what we envisioned. That’s the power of craftsmanship. When design, craft and going the extra mile with specialty finishes come together, the result resonates. It gets noticed. It’s remembered.  

Substrate Saturdays with Steve has been our weekly deep dive into the materials we work with at Thysse—breaking down what they are, how they function, and why they matter.

For our (maybe) final edition, we’re covering coatings, protectants, and specialty finishes—the subtle yet powerful details that don’t just protect your print but also enhance visual appeal, create texture, and make your brand stand out.

Whether you're designing packaging, signage, or high-end marketing materials, the right finish can turn something ordinary into something remarkable.

Coatings and specialty finishes serve three key purposes:

• Protection – Guarding against smudging, fingerprints, moisture, and general wear.

• Aesthetic Enhancement – Adding gloss, texture, or special effects to make materials stand out.

• Durability & Sustainability – Reducing waste by increasing durability and product lifespan.

A well-executed finish does more than preserve your print—it elevates and differentiates it.

Varnishes are one of the most affordable ways to add a subtle protective layer to printed materials. Applied inline during the printing process, varnishes enhance visuals and prevent smudging without significantly altering the substrate’s feel.

• Reducing scuffing and fingerprints on brochures, catalogs, and book covers.

• Adding a gloss, matte, or satin sheen for a polished finish.

• Creating design contrast with gloss and matte varnishes.

While varnishes offer light protection, they are not as durable or sustainable as modern coatings. For a greener and more protective option, aqueous and UV coatings are the preferred choice.

Aqueous coatings (AQ) are water-based, eco-friendly coatings that offer stronger protection than varnish while adding a smooth, uniform finish. These coatings contain fewer VOCs (volatile organic compounds), making them a more sustainable option compared to traditional solvent-based coatings.

• Gloss AQ – Produces a shiny finish that deepens colors and contrast.

• Satin AQ – A balance between gloss and matte for a soft sheen.

• Matte AQ – Reduces glare for a sophisticated, high-end feel.

Best For:

• Business cards, brochures, and catalogs needing vibrant colors and a protective layer.

• Packaging and retail displays that need added durability.

• Luxury print materials that require a premium look with an eco-conscious approach.

Aqueous coatings are a better environmental choice than older varnishes and laminates—offering a strong protective layer while still being recyclable.

For projects that demand high-end aesthetics and extreme durability, UV coatings are the gold standard. Unlike aqueous coatings, UV coatings cure instantly under ultraviolet light, creating a resilient finish that enhances color and provides superior resistance to scratching, smudging, and moisture.

• Gloss UV – Creates a high-shine, reflective finish that makes colors pop.

• Satin UV – A smoother, less reflective finish that adds a refined look.

• Soft-Touch UV – A luxurious, velvety texture that enhances perceived value.

• Spot UV – A contrast technique that mixes matte and gloss for a layered effect.

• Enhanced durability – Protects print materials from handling damage.

• Eco-friendlier than traditional varnishes – UV coatings are free from solvents and dry instantly, reducing emissions and waste.

• Stand-out branding – High-impact finishes give a premium feel that differentiates your brand.

Best For:

• Luxury packaging & premium brochures

• High-end business cards & invitations

• Retail displays & signage needing high durability

If you really want to make an impact, foil stamping and metallic effects add high-end embellishments that make your materials shine—literally.

Foil applications come in gold, silver, copper, holographic, and custom colors, giving materials a premium, upscale appeal. When paired with embossing or debossing, it creates a raised or recessed effect for added depth and texture.

• Luxury packaging and invitations

• High-end business cards and stationery

• Product labels & premium marketing collateral

Foil stamping instantly differentiates your brand, adding perceived value and exclusivity.

Throughout this series, we’ve explored a wide variety of substrates—each serving a unique role in branding, marketing, and communication. But it’s the finishing touches that set great brands apart.

• A soft-touch coating on a business card signals luxury and sophistication.

• A gloss UV finish on packaging enhances color and makes products pop on the shelf.

• A spot UV effect on a brochure draws the eye to key elements of a design.

• A foil accent on a label immediately elevates the perception of a product.

When every brand is competing for attention, the right finish doesn’t just protect—it helps you stand out.

At Thysse, we don’t just print—we craft brand experiences. Our expertise in coatings, specialty finishes, and material selection ensures that your printed materials don’t just exist—they make an impact.

If you're ready to explore coatings, finishes, or any of the substrates we’ve covered in this series, reach out! We’re here to help your next project exceed expectations!

Substrate Saturdays with Steve is our weekly series exploring the materials we work with at Thysse—breaking down what they are, how they function, and why they matter.

This week, we’re talking about paper—one of the most versatile and customizable substrates available. Whether you need a lightweight text stock for brochures, a sturdy cover stock for packaging, or an ultra-thick board for signage, paper remains a cornerstone of high-quality print materials.

At Thysse, we offer a wide variety of paper stocks to match different applications. From uncoated and coated papers to heavyweight board stock, our in-house selection ensures the right combination of texture, finish, and durability for your project. We get a lot of questions about paper selection, so let’s break it down into a little more detail:

When selecting paper for a project, weight and thickness impact not only the look and feel but also how it performs during printing, finishing, and handling. The right choice depends on whether the piece needs to be folded, scored, die-cut, or remain rigid.

There are two primary ways to measure paper:

• Weight (lbs) – Measured as the weight of 500 uncut sheets (a "ream") in its original size. Different paper types (text, cover, board) have their own weight scales.

• Thickness (Points or "pt") – Measured in thousandths of an inch (1pt = 0.001 inches). A higher point value means a thicker, more rigid paper stock.

The thicker the paper, the more likely it needs to be scored before folding.

• 10-12pt: Can be folded cleanly without scoring but may have slight cracking if heavily inked.

• 14-18pt: Best practice is to score before folding to prevent cracking and uneven creasing.

• 20-24pt: Requires scoring and is commonly used for packaging, retail displays, and premium marketing pieces.

• 30pt+ and Board Stocks: Too thick to fold—best for rigid signage, product backers, and premium packaging inserts.

• Die Scoring – Uses a metal rule to create a precise crease, commonly used for folders, greeting cards, and thicker brochures.

• Laser or V-Channel Scoring – Used for detailed, intricate folds on high-end packaging or specialty designs.

• Machine Creasing – Applies controlled pressure to bend without cutting, reducing cracking on coated papers.

• Marketing Collateral (Brochures, Flyers, Mailers) → 80-100lb text or cover, 8-12pt

• Business Cards, Postcards, Presentation Folders → 100-120lb cover, 12-16pt

• Luxury Invitations, Menus, Packaging Inserts → 140-160lb cover, 18-24pt (scoring needed)

• Product Packaging, Rigid Display Cards → 200lb+, 24-50pt board stock (no folding, only die-cutting)

Uncoated paper has no surface coating, giving it a soft, tactile feel and making it ideal for designs that require easy readability and a natural look. Coatings can prevent certain types of inks from adhering to the paper, so if writing on your project is part of the plan, uncoated papers are generally the way to go.

Best For:

• Books & Notepads

• Letterheads & Stationery

• Invitations & Event Programs

Coated paper has a smooth, treated surface that enhances production ink adhesion and color vibrancy. It comes in several finish types:

• Gloss Coated – Provides a high-shine finish for rich, deep colors.

• Matte Coated – Reduces glare while maintaining excellent print clarity.

• Silk Coated – A soft-touch finish that balances vibrancy and elegance.

Best For:

• Brochures & Catalogs

• Business Cards & Postcards

• Premium Marketing Materials

Cover stock, sometimes called card stock, is a thicker version of coated or uncoated paper, offering more rigidity and durability. It’s often used for premium printed pieces where structure and a professional finish matter.

Best For:

• High-End Business Cards

• Presentation Folders

• Packaging & Product Tags

Board stock is the thickest option we offer, available in weights up to 50-point thickness. This ultra-sturdy material is excellent for applications requiring rigidity and durability.

Best For:

• Short-Term Signage & Retail Displays

• Packaging & Box Covers

• Custom Die-Cut Promotional Pieces

With so many options available, selecting the right paper stock depends on functionality, aesthetics, and budget. At Thysse, we take the guesswork out of the process—helping you navigate and understand your options to determine the best one to meet your project needs.

In an increasingly digital world, physical brand assets still hold incredible power. The weight of a business card, the texture of a premium folder, the rigidity of a product package—these details shape how your brand is perceived.

Choosing the right paper isn’t just about aesthetics; it’s about functionality, durability, and the experience you want to create. A well-selected stock reinforces your brand’s identity, whether through the luxurious feel of a heavy cover stock, the practicality of a lightweight brochure, or the strength of a rigid board for signage.

At Thysse, we understand that every detail matters in crafting brand materials that leave a lasting impression. Our expertise in paper selection, finishing, and print production ensures that your physical assets aren’t just printed—they’re engineered for impact.

If you're unsure which stock is best for your next project, our experts are here to help. Let's create something incredible together—contact us today!

Substrate Saturdays with Steve is our weekly series exploring the materials we use at Thysse—breaking down what they are, how they function, and why they matter. This week, we’re exploring board stock—a versatile, lightweight substrate for short-term signage applications, packaging, pocket folders and more.

Board stock provides a cost-effective, recyclable, and high-quality print surface, making it ideal for a broad range of print solutions. Let’s break it down.

Board stock, sometimes referred to as paperboard or coated two-sided (C2S) board, is a paper-based substrate with a clay-coated surface on both sides. This coating enhances print quality, color vibrancy, and ink adhesion, delivering crisp, professional-looking results at an economical price.

• Lightweight & Cost-Effective – Available in multiple thicknesses, board stock is an affordable alternative to rigid plastic or metal substrates.

• High Print Quality – The C2S (Coated 2 Sides) surface delivers sharp, vibrant imagery and crisp text.

• Eco-Friendly – A fully recyclable material with a lower carbon footprint than plastic-based substrates.

• Best for Indoor Use – Can handle a mild, dry day outside, but exposure to moisture will weaken the material.

Board stock’s lightweight construction and affordability make it a go-to choice for indoor marketing applications. Here’s where it shines:

• Retail Signage: Ideal for in-store promotions, shelf talkers, and temporary product displays.

• POP Displays: Used in point-of-purchase signage where high-quality graphics matter.

• Event Signage: Great for conference and trade show signs where durability is not a primary concern.

• Menu Boards & Posters: Works well for indoor menu boards, sale announcements, and wall posters.

• Backdrops: A budget-friendly option for temporary set pieces and even photo backgrounds. (Printed fabrics also work well for this, depending on fixtures and other needs.)

• Packaging: Commonly used for card and folding carton packaging

• Pocket Folders: A brand staple across virtually every industry and made with board stock.

At Thysse, we keep two standard board sizes in stock:

• 48” x 96”

• 50” x 100”

Board stock is easy to trim, die-cut, and crease for custom signage needs. Thysse’s array of die cutters and incredibly precise, computer-guided flatbed cutters can cut, blank and score board stocks to your specifications.

Board stock is not designed for long-term outdoor applications. While it can handle a mild, dry day outside, exposure to moisture or humidity will cause the material to weaken, warp, or disintegrate.

For weather-resistant signage, consider alternatives like:

• Coroplast (corrugated plastic) – Durable and waterproof, great for yard signs.

• Foam PVC (Sintra, Komatex) – More rigid, with excellent moisture resistance.

• ACM (Aluminum Composite Material) – Long-lasting and ideal for high-end branding.

Board stock remains one of the most cost-effective and reliable substrates for high-quality print products ranging from signage and folders to retail packaging. It provides an eco-friendly alternative to plastic-based materials, prints beautifully, and is easy to work with across all the different forms it can take.

Whether you need vibrant signage, premium packaging, or high-quality folders, board stock is a cost-effective, eco-friendly solution that delivers exceptional print results.

Need help choosing the right substrate? Our experts at Thysse can guide you through the best material for your signage needs. Contact us today, or check out our growing library of resources!

When it comes to print, there’s craft—and then there’s Thysse. We’re thrilled to share that our team took home multiple accolades at the 2025 Graphics Excellence Awards, hosted by the Great Lakes Graphics Association (GLGA). In total, seven print pieces earned a total 8 awards including:

• One Best of Category (aka Best in Class)

• Seven Awards of Excellence

• Two Certificates of Merit

While we’re proud of the awards themselves, it’s the stories behind the pieces—and the collaboration, innovation, and purpose that went into them—that really shine.

Awards: Best of Category (Cards), Award of Excellence (Variable Data Digital Printing), Certificate of Merit (Innovative Printing)

A snowy alpine scene, a hidden sleigh in the sky, and a journey that begins with a map.

Our 2025 holiday card pulled out all the stops. The cover featured a serene nighttime winter landscape with hidden, light-sensitive dispersion elements that revealed Santa and forest wildlife only when the light hit just right. Inside, metallic foil snowflakes and swirling wind lines surrounded a personalized map, showing the actual driving route between Thysse and the recipient’s business. Each card was further customized with the recipient’s name and a photo of their Thysse account contact—making the message, "From our family to yours... here’s to the journey ahead," truly heartfelt.

Built with an offset press shell, variable digital data, and foil stamping, the card blended multiple technologies in a seamless and beautifully executed way.

For clients exploring how to elevate year-end communications or connect on a more personal level, this project shows how thoughtful print design can make a lasting impression.

Awards: Award of Excellence (Service Catalogs), Award of Excellence (Embossing/Debossing)

Sometimes, less really is more. Our Facility Branding Look Book was a study in elegance and restraint. Crafted on premium black stock with a tactile, soft-touch finish, the cover featured a debossed topographic line motif with a gold foil-stamped Thysse logo. Inside, readers found a curated collection of past Facility Branding projects—an inspiring look at what our team can help bring to life.

If you’re considering an environment refresh or want to better reflect your brand in physical space, this piece is a glimpse into the possibilities, and we’d be happy to mail you one.

Award: Award of Excellence (Internal Communication Pieces)

Shared with every member of Team Thysse, our 62-page employee handbook is more than policy—it’s a deeply significant wayfinding guide. Inside are the values, behaviors, and commitments that define who we are, including a letter from our owner, our history, and illustrations of what makes Thysse one of the most sought-after places to work in our industry. The power of a vibrant, healthy culture benefits everything it touches, internally and externally. Like all things healthy, it takes dedication, action and effort to nurture–and this is one of the many ways Thysse does it.  

If you're building culture and connection inside your organization, your internal materials deserve just as much attention as your external ones.

Award: Award of Excellence (Newsletters)

Folded like a traditional broadsheet newspaper, Press & Pixel is our internal newsletter and a labor of love. Every issue contains department updates, personal milestones (babies, birthdays, retirements), and even playful KPIs like how many types of coffee or tea we’ve consumed since the last issue, and how many! More than just updates, it keeps our team connected, informed, and smiling…another manifestation of our commitment to investing in our team culture.

It's a reminder that even small touches in internal communication can foster stronger alignment and community. The byproduct is, as we like to say, “good things happen.”

Awards: Award of Excellence (Calendars), Award of Excellence (Foil Stamping)

Each year, we challenge ourselves to make our calendar more creative than the last. The 2025 edition was all about maps: treasure maps, cloud maps, metro maps, even a cork map with client pins. Foil embellishments transformed the July "strata" map into a molten, abstract American flag. The calendar also included perforated bonus year-at-a-glance pages for 2025 and 2026—tactile, useful, and a pleasant surprise.

For brands looking to push creative boundaries and offer unexpected value, this calendar is a case study in how design, function, and storytelling can come together. And, stay tuned for more behind the scenes looks into the 2026 calendar, already in development! This year, we’re sharing the entire process.

Award: Certificate of Merit (Environmentally Sound Materials)

At first glance, it looked like a standard plastic ID card. But this badge was different. Made from a paper-based, sustainable substrate with the look and feel of plastic, it represented a small but meaningful step toward reduced waste. The bulk of the work was really on our sourcing and testing teams, and they hit it out of the park.

For organizations committed to sustainability, it's proof that even routine materials can reflect intentional, responsible choices. While a humble piece in terms of format, the innovation behind the material earned it a well-deserved nod.

The Graphics Excellence Awards celebrate the very best in printing across Illinois, Indiana, and Wisconsin. These awards affirm not just the quality of our work, but the pride, curiosity, and craftsmanship we pour into everything we do.

To our clients: thank you for trusting us to help bring your brands to life. And to our team: congratulations on continuing to raise the bar. Let’s keep making print that connects, inspires, and wins.

Stay tuned as we celebrate each piece with photos, behind-the-scenes details, and the amazing people who made them happen. We're already hard at work on the 2026 calendar—an annual tradition that blends concept development, materials testing, structural innovation, and more than a few late-night print runs. This year, we’ll be pulling back the curtain to share more of the journey behind the final piece that ends up on desks, walls, and workspaces across the country.