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A quarter-century ago, David Saylor shepherded the epic Harry Potter fantasy series onto U.S. bookshelves. As creative director of children’s publisher Scholastic, he helped design and execute the American editions of the first three novels in the late 1990s.

But when the manuscript for J.K. Rowling’s fourth book landed on his desk, Saylor sat up straight: It was huge. Bigger, more complex and narratively intricate than virtually any storybook ever aimed at children.

“I had to really think,” he said in a recent interview. “‘How are we going to typeset this book? How are we going to print a million copies? How are we going t

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