All Hail Humble Chipboard

One might say my love of letterpress started with chipboard. I recently chuckled over a delivery of this recycled wonder in the shop as it made me pause to marvel at its humble magnificence. This batch was two-tone… two very different shades on each side, as shown by this month’s Print Club postcard.

Chipboard is a 100% recycled material designed for multiple utilitarian uses. And we definitely use it this way as evidenced by a look around the studio. Nearly every cutoff is saved for padding paper in the guillotine, collecting unwanted ink, packing orders, bulking up prints, etc.

Back in the 90’s, I took breaks from university studies by visiting record stores, which ultimately meant stumbling over new ideas in music packaging. At the time, CDs were king and this meant a considerable amount of plastic. Those that bucked the system immediately stood out; they were printed on chipboard packages! This magic immediately caught my eye and to my delight, I discovered many were made here in Chicago at Fireproof Press. Fast forward a few months and I got a job there while continuing to build a collection of unique packaging. Below are a few projects we printed at Fireproof and one CD by John Upchurch (the man behind Fireproof) that was printed at Starshaped.

These are a few records and CDs printed by Independent Project Press using chipboard as well.

Many of these packages were pre-fab and ideal for the versatility of a platen press. They came from Calumet Carton, not far from Chicago. They no longer offer CDs but I still purchase all of the mailers for the studio from them.
Below are a few of the music packages printed at Starshaped. You can see how even with similar packages, the chip itself shifts in color and sometimes texture.

Chipboard has shown up for a number of studio projects over the years, including this silent film-inspired poster for an annual open house. This particular stock had a grayish cast and was perfect for the job.

Chipboard is also the first choice for CHIRP Radio projects! These are a few of the invitations and cards we’ve done together over the years.

I’ve also used chipboard for a number of prints in the studio, including both of these below. The ampersand uses the back sides of wood type blocks to print translucent rectangles that allow the chipboard texture to show through. The snowy barn demonstrates how the color of chip can work for printing both light and dark colors.

The Dollhouse Gig Posters project in 2016 was an opportunity to combine all of these loves together. Each month of the year, I produced a tiny, 2x3” ‘poster’ of a musical genre and subscribers received them in the mail. The tiny posters were mounted onto 7” square chipboard showing what genre it was, with a nod to 60s-style ‘collect them all!’ design sensibilities.

And here’s a recent job for Mark Lerner, a longtime fan of the almighty chipboard and letterpress combo!

Chipboard features heavily in the Print Club. Not only is the postcard used to share info about the Club printed on it, but the monthly postcards are as well. You can see by the collection of postcards here that the chip itself changes over time with each delivery, even as the spirit of each design remains the same. It’s my favorite piece to create for the Club each month.

I get chipboard from Andrews Paperboard, the same place that supplied Fireproof back in the day. Again, I like to keep it local, and my delivery driver pal, Steve, always brings a laugh when he shows up with a pallet of fresh, newly recycled chipboard. It’s not the fanciest paper, it’s not high class, it’s often inconsistent in appearance and wasn’t designed necessarily for ‘lofty’ letterpress. But chipboard is the great equalizer and when it moves on from my shop, either in the recycle bin or for finished projects, it has every opportunity to become a fresh, new project for another lover of the mighty, humble chipboard.

Announcing Extra! Extra!

The thing about print that’s always grabbed me, that’s always inspired me to keep pushing forward, is the tangible result of piecing together ideas. It’s the creation of a physical artifact that connects you to a moment in time. There’s a reason we delight in ephemera of the past, even if we don’t see the immediate importance of its modern counterpart.
I was drawn to the DIY culture of the 90s because it gave folks ways to find their voice outside of established, often inaccessible channels. I spent time with kids making their own zines, films, records, protest banners, movements, you name it. It was a great, messy time of figuring it out the hard way, in an environment where ‘social media’ meant meeting up at the local coffee shop.
When I first put Starshaped on Instagram 10 years ago (at the behest of a great intern), it was a lot of fun. The print community found each other quickly and relationships were formed. Projects were shared. Collaborations developed. Opportunities explored. In recent years I’ve seen this drift away in favor of non-content, the commodification of every little thing as well as the rise of nouveau snake oil salesmen. I, too, have drifted away from giving a s**t about what happens in this sphere. With the recent, full unmasking of Meta’s goals, I knew it was time to make moves.

Some of the first Instagram posts for the studio. Oh the filters!


Owning the means of production prior to the advent of social media has given me at least a rudimentary understanding of how to reach people outside of this domain. There was a time when all correspondence with the studio was via print, in person or through marketing on hyper-focused blogs. While the shop is in the great position to not have to market aggressively these days, it’s important to me that the work is shared because it’s part of the history of print and design. Materials have passed to my hands from generations past and I hope to pay this forward.
Knowing that I don’t want to actively partake in systems that ultimately harm myself and those I love, I’m planning to move content to the medium I DO control. Extra! Extra! is a new series of postcards mailed throughout the year (working on frequency now) to anyone interested in receiving them. They’ll highlight type in the studio and point to blog posts right here that share the kinds of bits & bobs that would normally appear on social media. I understand this has less reach than Instagram (though that’s debatable with an algorithm that doesn’t care about actual followers vs. the idea of followers), but it gives me total control. And it’s free for everyone.

A screenshot of the front of the first card, about to head into production. These are designed to showcase type and ornament in the collection, reversed for easy reading and display-ready.

The postcards will be offset printed by my pals at NS Printers, a wonderful, women-owned union shop in Waukegan, Illinois. This method has two benefits: it’s cheaper and faster than letterpress-printing all of the cards and allows me to share images of the type with easy QR codes that point viewers to the site with more details.
Each will include items such as:

  • Interesting type facts… including images of unique fonts in the shop

  • Historical tools of the trade

  • Shop life

  • First dibs on new prints

  • Retired/Limited Edition prints pulled from the flat files

  • Printers, vendors and non-profits we love

  • Sales and Last Call prints & cards


If you’d like to receive postcards in the mail, please sign up through the link at the top! I’m happy to have you and look forward to sharing the studio in the ways I know best! If you’re a member of the Print Club, you’ll receive postcards with your monthly mailings. Thanks for keeping the studio vital for 25 years.

EXTRA! EXTRA!

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EXTRA! EXTRA! **