CD Cover Dimensions: Inserts, Tray Cards and Print Bleed Explained
A replacement CD cover can look perfect on screen and still buckle inside its case or leave the spine title hidden around a fold. Getting the fit right means measuring each paper component separately. The front insert, folded booklet and rear tray card have different dimensions, and the artwork needs extra space wherever it will be trimmed.
These CD cover dimensions provide a useful starting point, followed by a practical method for checking your own packaging before printing.
Common CD cover dimensions
For a conventional jewel case, the usual reference sizes are 120 × 120 mm for the front insert and 150 × 118 mm for the rear tray card, as described in Wikipedia’s overview of optical disc packaging.
All measurements below are width × height, with the paper lying flat. They exclude bleed.
| Component | Typical or example dimensions | What to check |
|---|---|---|
| Front insert or booklet page | 120 × 120 mm, approximately 4.72 × 4.72 inches | Some templates specify slightly different dimensions |
| Four-page folded insert, opened flat | 240 × 120 mm for two 120 mm panels | Confirm the actual panel widths and fold position |
| Complete rear tray card | 150 × 118 mm, approximately 5.91 × 4.65 inches | Includes both spine strips |
| Rear centre panel | 138 × 118 mm in a layout with two 6 mm spines | Width depends on the specified spine dimensions |
| Each spine strip | 6 × 118 mm in that example | Measure both strips independently |
Use the template for your particular packaging whenever one is available. Supplier specifications vary: a front insert might be 121 × 120 mm, while a tray card might be 150 × 117.5 mm or 151 × 118 mm. Small differences can affect both fit and fold alignment.
How to measure jewel case inserts
A millimetre ruler, a flat surface and an existing insert that fits well are usually enough.
Front insert and booklet
Remove the paper from the front lid and measure its trimmed width and height. Measure the paper itself; the outside dimensions of the plastic case include hinges, borders and other space unavailable to the insert.
For a folded insert, record:
- Its closed width and height.
- Its complete width when unfolded.
- The position of every fold.
- Its thickness when closed.
A four-page insert has two panels printed on both sides. Two 120 mm panels produce a flat width of 240 mm; two 121 mm panels produce 242 mm. Follow the measured or specified layout rather than assuming every folded insert is exactly twice the nominal 120 mm cover width.
For a stapled booklet, check the printer’s page setup instructions. A thicker booklet may need adjustments for the way nested sheets project towards the outer edge, known as creep.
Rear tray card and spines
The tray card sits underneath the plastic disc tray. Remove it carefully, if the tray can be released, and open the spine folds without stretching the paper.
Measure the full width, height and distance between the two folds. Then measure each outer edge to its nearest fold.
The relationship is:
Full tray card width = left spine + centre panel + right spine
For example, a 150 mm card with two 6 mm spines has a 138 mm centre panel. Its fold lines sit 6 mm and 144 mm from the left edge.
The CD tray card size includes the spine strips. Adding spines to an already complete 150 mm layout would make the card too wide. Also, the case’s external thickness does not determine the printed spine width.
Trim, bleed and safe margins explained
These three boundaries serve different purposes.
Trim: the finished paper size
The trim line marks where the paper will be cut. A 120 × 120 mm front insert should measure that size after trimming.
Set your document’s trim size first, then add the bleed required by your printer.
Bleed: artwork beyond the cut
Bleed extends backgrounds and edge-to-edge images beyond the trim line. It allows a slight cutting variation without exposing an unwanted white strip.
A common requirement is 3 mm on every outer edge, although some suppliers specify a different amount.
With 3 mm bleed on each side:
| Finished trim size | Artwork extent including bleed |
|---|---|
| 120 × 120 mm front insert | 126 × 126 mm |
| 150 × 118 mm tray card | 156 × 124 mm |
The calculation adds the bleed twice to each dimension: once at each opposing edge. Crop marks, if requested, sit farther outside this area.
An internal fold normally needs no separate bleed because the sheet remains continuous across it. Keep the background continuous through the fold.
Safe margins: essential content inside the cut
Safe margins protect lettering, logos and important image details from trimming variation.
For broad panels, keeping essential content at least 3 mm inside the trim line is a useful starting point. Keep track lists and other small text clear of folds too.
Narrow spines need their own allowance. Applying a 3 mm margin to both sides of a 6 mm strip would leave no usable width. Centre the lettering within the spine and follow the template’s specific safety guides.
Packaging variations that need a separate template
A familiar-looking case does not guarantee familiar insert dimensions.
- Slimline jewel cases: Many accept a front insert but have no provision for a conventional rear tray card.
- Multi-disc cases: Some use standard artwork; others need different back cards, booklets or spine layouts.
- Super Jewel Boxes: Their rear inserts differ in shape and dimensions from conventional jewel case cards.
- Card sleeves and digipaks: Panel widths, pockets, glue tabs and folds depend on the manufacturer’s cutting template, often called a dieline.
For folded card packaging, measure both the closed package and the full unfolded structure where possible. A cover image alone does not reveal the allowances needed for pockets or glued seams.
Printable CD artwork measurement checklist
Print this checklist and complete it using your actual packaging or the supplier’s template.
Measurements
- Packaging type and template version: ____________________
- Front insert, finished width × height: ______ × ______ mm
- Folded insert, full flat width × height: ______ × ______ mm
- Complete tray card, including spines: ______ × ______ mm
- Rear centre panel width: ______ mm
- Left spine width: ______ mm; right spine width: ______ mm
- Fold positions measured from the left edge: ____________________
- Paper thickness and booklet fit checked.
Artwork and printing
- Required bleed on each outer edge: ______ mm
- Safe margin for essential panel content: ______ mm
- Spine lettering fits within its safety guides.
- Front, back and spine text orientation checked with a folded mock-up.
- Backgrounds extend through the bleed area.
- Template guides will be hidden in the final artwork.
- Print scaling is set to 100% or Actual size.
- A printed measurement check confirms the intended scale.
- One trimmed and folded proof fits comfortably inside the case.
Check image quality before the final print
Correct dimensions cannot compensate for a small, blurry source image. At 300 pixels per inch, a 120 mm square cover needs approximately 1,417 × 1,417 pixels at its finished size. An image covering a 126 mm square area, including bleed, needs approximately 1,488 × 1,488 pixels.
Changing the resolution setting alone does not restore missing detail. Keep text as editable type or vector artwork where possible, and preserve an original image separately from the print layout.
Print one proof on ordinary paper first. Measure it, trim it and fold it before testing the fit. Then repeat with your chosen paper stock, since thickness can change how easily an insert slides beneath the tabs and how neatly the case closes.