Patent ID: 8437687

Claim:
A method of producing a booklet, the booklet including an outer sheet and an inner sheet folded in a fold direction and nested together, each sheet having a respective thickness, the outer sheet having a length in a specific direction, and a fold axis of the outer sheet being defined in the center of the outer sheet in the specific direction, each sheet having an inside face and an outside face, wherein the inside face of the outer sheet is adjacent to the outside face of the inner sheet when the sheets are folded and nested, the method comprising: printing a print image on the outside face of the inner sheet or the inside face of the outer sheet using a print engine; calculating a thickness for the print image; using a processor to calculate a cut length in the specific direction of the inner sheet using both at least a known thickness of the outer sheets and the calculated thickness of the print image, so that when the sheets are folded and the inner sheet is nested into the outer sheet, the edges of the inner sheet will not protrude beyond the edges of the outer sheet; using a cutting device to cut the inner sheet to the calculated cut length in the specific direction, either before or after printing, so that a fold axis of the inner sheet is defined in the center of the inner sheet in the specific direction; automatically folding the cut inner sheet and the outer sheet along their respective fold axes, wherein the cut inner sheet is folded after the printing step; and automatically nesting the printed sheets together to produce the booklet.