Chapter 25 - Working with Papers & Boards

What is the definition of 'deform' in the context of materials manufacturing?

It is a change in the shape of materials when they are put under physical pressure or stress.

What type of manufacturing process changes the shape of a material without removing any parts?

A deforming process.

Small-scale deforming processes often use simple, ________ tools.

manual

What manual tool is used to apply force along a fold line for accuracy when folding paper by hand?

A bone folder.

What is the process of using a tool to create an impression on paper to facilitate folding by hand called?

Scoring.

What is the definition of 'embossing'?

A printing technique that creates a raised design or pattern on paper or boards by pressing them with a tool.

Name two simple manual tools used for small-scale embossing.

A stylus, soft mats, stamps, mallets, or hammers.

What is a 'die' in the context of embossing?

A tool, which can be handmade, used to press a design onto a material.

Constructing a paper or card net is an example of what manufacturing process?

Deforming.

The process of deforming paper to produce a wavy, zig-zag texture by pressing it through rollers with ridges is known as _________.

crimping

What are three benefits of adding a crimped texture to paper or board?

It adds strength, flexibility, and a decorative element.

What is the paper craft technique that involves rolling, shaping, and gluing thin strips of paper to create decorative designs?

Quilling.

List two benefits of small-scale deforming processes.

They are low cost, easy to set up, good for one-off prototypes, and can achieve detailed bespoke shapes.

List two limitations of small-scale deforming processes.

They are time-consuming, require skill and patience, and are limited to smaller or thinner materials.

Why are industrial deforming processes used for large-scale manufacturing?

To increase speed, accuracy, and consistency.

What does CNC stand for in manufacturing?

Computer Numerical Control.

What is a 'former' in an industrial deforming process?

A tool over which material can be formed using force.

What is the difference between a negative and a positive former?

A negative former is a hollow shape the material forms into, while a positive former is a raised shape the material forms over.

How does industrial embossing typically work?

Material is pressed between a negative and positive former under controlled force, and sometimes heat.

What is industrial braille embossing used for?

To create raised braille dots on packaging or printed materials to make information accessible for visually impaired users.

What industrial process uses creasing rules with blunt edges?

Industrial die-cutting and creasing.

What is the purpose of 'creasing rules' in industrial die-cutting?

To create fold lines without tearing the material.

Industrial corrugation is performed on large machines called ___________.

corrugators

In industrial corrugation, softened paper is passed between two large metal cylinders with gear-like teeth called __________ rollers.

corrugating

What is the term for the wavy pattern pressed into paper during corrugation?

A fluted pattern.

What is the purpose of automated folding and gluing machines in industrial settings?

To automatically fold pre-creased areas and apply adhesive to assemble flat-cut paper and boards into a finished product.

Why are dies and formers in industrial settings often made from metal like aluminium or steel?

Because they are strong, highly accurate, and durable enough to withstand heat, pressure, and repeated use.

What is a 'wasting process' in manufacturing?

A method where material is removed to shape or finish a product.

For paper and boards, wasting processes include methods like cutting, ________, and perforating.

punching

Which small-scale hand tool is best suited for making accurate straight line cuts in paper and boards?

A craft knife or scalpel (used with a cutting mat and safety rule).

What is the function of a guillotine in paper and board manufacturing?

It uses a sharp blade to 'slice' or cut paper or thin card accurately.

What type of power tool with a continuous loop blade can quickly cut straight lines and curves in thicker paper and boards?

A bandsaw.

What is the wasting process which produces holes or shapes using a punch tool called?

Punching.

What is the purpose of 'perforating' a material?

It is the process of creating small holes or cuts for easy tearing or folding.

What is 'die-cutting'?

A process that uses a die with sharp steel edges to cut out shapes, commonly for greeting cards and packaging nets.

What is one key advantage of using CNC machinery in industrial wasting processes?

It can cut complex and precise shapes repeatedly with minimal human intervention, ensuring high production speed and consistency.

Compared to industrial die-cutting, industrial laser cutting is not as fast and is typically reserved for _______ pieces.

complex

What is one advantage of industrial CNC cutting machines over laser cutters for paper and card?

They use a sharp blade instead of a laser, which leads to a cleaner finish and avoids burnt edges.

What defines a 'reforming' process for paper and boards?

It changes the shape or structure of a material, often by reshaping pulp fibres, without changing its basic chemical structure.

A small-scale example of reforming paper is making handmade paper, which is essentially making _________ paper.

recycled

What is produced when you mix pieces of paper with water and blend them?

Pulp.

What is the difference between a 'mould' and a 'former' when shaping paper pulp?

A mould is a hollow shape that pulp is pressed into, while a former is a solid object that pulp is shaped around.

The process of soaking paper in a glue or paste mixture and layering it over a former or into a mould is called ______ ______.

papier mâché

What are three key benefits of industrial reforming processes using automated methods?

They ensure speed, accuracy, and consistency.

What is 'pulp moulding'?

An industrial reforming process that uses recycled paper pulp to form shaped products using moulds, such as egg cartons.

List the five main steps in the industrial process of pulp moulding.

1. Pulp creation, 2. Forming in a mould, 3. Pressing to remove water, 4. Drying, 5. Trimming.

What is 'bonding' in the context of reforming paper and board?

Joining layers of paper or cardboard together using adhesives or other methods to form a stronger or more functional material.

_________ bonding uses glue like PVA to stick layers of paper or board together, common in lamination and corrugated board.

Adhesive

What type of bonding, often used in food packaging, uses heat to melt a layer of plastic or wax to bond sheets?

Heat sealing.

What material is made by bonding a layer of foam between two outer layers of paper?

Foam board (or foam-core board).

What is the difference between recycling and upcycling paper?

Recycling involves breaking the material down (e.g., back to pulp), while upcycling reuses it in its current form without major processing.

List two environmental benefits of recycling paper and boards.

It reduces deforestation (tree felling), saves energy, and prevents waste from going to landfill.

What are the six main stages of the industrial paper recycling process?

1. Paper collection, 2. De-inking, 3. Cleaning chambers, 4. Pulpers, 5. Paper making rollers, 6. Recycled paper.

What is the term for a way of holding materials together using physical means like fasteners or shaped joints?

Mechanical fixings.

What is 'chemical joining'?

The process of bonding materials using substances (adhesives) that create a chemical reaction to hold parts together.

What type of mechanical fixing, also called a paper fastener, is inserted through a hole and has two metal legs that are splayed to secure materials?

A split pin.

What is a major benefit of using split pins to join paper components?

They allow for rotation of the joined pieces.

What is a limitation of heavy-duty cardboard staples used in packaging?

They are difficult to remove, which creates challenges for recycling the cardboard.

What is the main difference between a wire paper clip and a binder clip in terms of capacity?

A wire paper clip is for a few sheets, while a binder clip can securely hold much larger stacks (e.g., up to 100 pages).

What are cardboard folding tabs and slots?

Interlocking design features that allow pieces of cardboard to be joined without glue or components.

A ____ tab is often used in packaging, where the tab folds into a slit to close a box.

tuck

What is the process of securely joining pages together to form a single unit, such as a book or booklet, called?

Binding.

What type of binding involves a plastic or metal coil threaded through punched holes along the edge of the paper?

Spiral binding.

______ binding is common in high-end books and journals, where pages are sewn together with thread for durability.

Sewn

What does PVA stand for, and how does it chemically join porous materials like paper?

Polyvinyl acetate; it soaks into the material and forms a strong bond as the water evaporates.

What type of adhesive is applied as a fine mist from an aerosol can and is ideal for bonding large surfaces evenly?

Spray adhesive.

Which chemical joining tool melts solid glue sticks to dispense hot adhesive for a quick-setting, strong bond?

A hot glue gun.

What is a 'stock form'?

The standard shape or size a material is supplied in.

How are papers and boards measured to distinguish between them?

By weight, in grams per square metre (gsm).

A material under 200 gsm is considered , while a material over 200 gsm is considered .

paper, board (card)

How is the thickness of board sometimes measured?

In microns, where one micron is 1/1,000th of 1 mm.

What does 'ply' refer to in paper and board stock forms?

The number of layers (plies) that are bonded together for strength or absorbency.

List two benefits of having materials available in standard stock forms.

They are easier to store/transport, lower costs, increase efficiency, and reduce waste.

What is the relationship between paper sizes in the A-series (e.g., A3 and A4)?

Each size is half the area of the one before it (e.g., A4 is half the size of A3).

What property of layout paper makes it suitable for graphic drawings?

It is lightweight, thin, cheap, and has a smooth surface.

Why is bleed-proof paper suitable for use with marker pens?

It contains more chalk and has a hard surface that doesn't absorb ink, preventing it from bleeding.

What is the primary use of corrugated cardboard?

Packaging protection during transportation and for packaging some hot foods due to its insulating properties.

What is duplex board commonly used for?

Food packaging, such as biscuit boxes or containers.

What type of board has an aluminium foil lining that acts as an excellent barrier against moisture?

Foil-lined board.

What is the process of enclosing paper or board in a plastic sleeve, which is then heated and pulled through rollers, called?

Laminating.

What is 'sizing' in paper manufacturing?

The addition of a chemical to paper to give it a protective glaze, making it resistant to liquid.

What is the purpose of adding a UV glossy coating to card?

To give it a high-gloss finish, which is more environmentally friendly than laminating as there is no polymer to separate during recycling.