Hi Kevin –
You’ve just run into one of the major stumbling blocks of multiple device/format delivery. There are a couple of ways to go, neither of which is simple. Let me preface this with the first rule: find out as many of the delivery formats before you start the project, if you can. This will give you the chance to plan. If you know your smallest device plays back at 640 x 360, create a project in which you lay down some sample screens, making them readable. And leave a little leeway for people with not so great eyesight. This will give you a benchmark, and you’ll know that everything will read fine when it’s sized up. This is, of course, if you want to just do a single version and apply it to all delivery formats.
Another possibility (which is more work), is to do different versions of the graphics for, say, DVD playback and web delivery. On the web, you have more room for your graphics, since there is no title safe to worry about. If you edit a clean version of the production, you can then drop the video into your graphics templates – I would do this in After Effects myself, but I’m sure you could nest it in Premiere.
Another possibility is to make sure that any important graphics are read in the voice-over. This makes the smaller text not as important if it’s tough to read. If you have bullets, have the bullets read. Lower thirds aren’t so simple – they have to be readable. Lots to think about, as I said.
Joe Bourke
Owner/Creative Director
Bourke Media
http://www.bourkemedia.com