DT

• Die Cutting -

  • Uses papers and boards
  • Sharp blade for cutting
  • Round blade for perforations
  • Used in commercial processes
  • Even force applied by pressing to ensure uniform cuts
  • Quick -
• Offset Lithography Printing -

  • Used in mass production
  • Prints in black, magenta, cyan and yellow ink
  • Ink and water applied to rollers from plate rollers
  • Water keeps roller wet to avoid ink sticking
  • Image from plate cylinder transferred to rubber offset cycling before transferred to final material
  • Process repeated for each colour
• Understanding Colour -

  RGB and CMYK are colour processes
• Lithography -

  • Used for high volume, commercial prints
  • Printers can print on both sides
• Scales of Productions (4):

  • One-off production
  • Batch production
  • Mass production
  • Continuous production
• One-off production:

  • A single product or unit is made
  • Prototypes are classified
  • Personalisation is customised to fit the criteria
• Batch product:

  • More than one unit is produced at a time
  • Patterns, templates or jigs increase efficiency
  • Production lines are flexible
  • Have short lead times
  • Seasonal
• Jigs and Templates:

  • Make a process easier
  • Jigs can be used in one-off and batch production
  • Can do repetitive tasks against
  • Identical standard and quality
  • Minimises waste
• CNC Machines:

  • CNC - Computer Numerical Control
  • Computer aided design machines e.g. laser cutters
  • Often used in batch production
  • Accurate and efficient
  • Flexible
• Mass Production:

  • Made in large volumes
  • Factories with high level of automation
  • Few processes completed by hand
  • High set-up costs and low units cost
• Set-up Costs:

  • The more automation in a production line, the higher the set-up costs will be
  • Products with machinery are mass produced
• Continuous Production:

  • Non-stop, 24 hours a day
  • Manufacturing products to meet constant demand
• Force = mass x acceleration
• Compression: How much load can withstand something before failure
• Tension: Being drawn or stretched out
• Torsion: Twisting a material
• Bending: The force applied causing a material to bend
• Shear: Opposite forces act on a object in a direction perpendicular to its length
• Recycling:

  Primary recycling: reusing without modification

  Secondary recycling: modifying a product for a different purpose
• How is paper made?

  1. Trees are cut down
  2. Trees are debarked and chipped
  3. Cooked with chemicals
  4. Cellulose fibres
  5. Sizing
  6. Drained
  7. Squeezed
  8. Calenders
• Stock forms (3)

  • Rolls
  • Sheets
  • Ply
• What can be used to cut materials to size?

  • Guillotine
  • Laser cutter
  • Craft knife
• What can be used to score and crease materials?

  • Creasing tool
  • Craft knife
• What can be used to reform and deform (reshape) materials?

  • Craft knife
  • Scissors
  • Laser cutter
• What can be used to add perforations?

  • Perforator
• Standard weight:

  Papers and boards are measured by weight (gsm) or thickness (microns)
• Why having standard sizes is good:

  • Often easier
  • Often cheaper
  • Products like frames/accessories can be made to fit standard sizing
• Standard sizing:

  A sizing: Used at school

  B sizing: Used in industry

  C sizing: Used in envelope
• Different types of binding methods:

  Saddle stitch: programme or guidbook

  Perfect bound: textbook

  Comb bound: short report
• Embossing:

  1. Involves creation of two plates: relief die (female) and counter die (male)
  2. Paper of board placed between two dies
  3. When compressed, fibres stay in position
• Foil blocking: gives a premium finish
• UV spot varnishing: Uses a mark to apply a gloss finish to unmasked areas
• Laminating:

  1. Paper or board placed in plastic sleeve
  2. Heated and put through rollers, sealing product

  Effect:

  • Shiny
  • Water-resistant surface
  • Thick
  • Durable
• The 6 Rs -

  • Reduce
  • Reuse
  • Recycle
  • Rethink
  • Refuse
  • Repair
• Registration mark - check alignment of printer
• Die Cutting - arrangement of blades produces a net
• Crop marks - to show where to cut on a sheet of paper
• Colour bars: checks colours are printed to correct consistency and intensity