The success of a quality Embossing process hinges on selecting the appropriate substrate thickness. If the paper or board is too thin, the intense pressure from the die and counter-die can cause the fibers to rupture, leading to tears or cracking, especially around sharp corners. Conversely, working with overly thick board may require exceptionally high press tonnage, potentially causing surrounding areas of the substrate to deform or the detail of the emboss to be flattened slightly.

Fiber type is also critical; materials with long, strong fibers, such as cotton paper, tend to hold the embossed shape better and are less prone to cracking than those with short fibers. Consultants recommend pre-testing the selected substrate with the specific die design to ensure the paper fibers can handle the stress and maintain the desired tactile and visual longevity of the embossed effect.