Identify the skill level, age and knowledge of the topic of the person likely to use the manual. Determine where and how often the manual will be used and if the person will need to hold the manual while completing the steps. Write the content and choose the size to fit that audience. Proof your manual before printing and finishing to make sure all errors are caught.
Lay out your booklet in the determined size. It should include: a title page, a table of contents, an introduction, step-by-step instructions and a conclusion. It may include detailed graphics, photographs or other visual aids. It should also include front and back covers. The front cover should illustrate the contents and be dynamic and attractive.
Position your content so that the pages will print to form a signature. A signature is a large sheet of paper with several smaller pages printed on it that is folded to page size before assembly. This way, when the pages are assembled, they will be in the correct reading order. The design of your signature will depend on the finished size of the booklet and the size of the printing paper. Smaller booklets often have more complex signature designs. Typical signature layouts can be found online, in books or through professional printers.
Print and assemble the signatures that comprise the booklet. Fold the signature to the correct page size. Bind the booklet together using staples, glue, plastic or metal combs, stitching, or other methods. Finish the booklet by trimming the top, bottom and right side for a professional, finished appearance.