Chapter 26 - Commercial Manufacturing, Surface Treatments & Finishes

What is the term for the acceptable amount by which a measurement can vary without affecting the product's accurate manufacture?

Tolerance.

What is 'Quality Control (QC)' in the context of manufacturing?

A set of checks made on a product before, during, and after production to ensure it meets quality, safety, and specified customer requirements.

In printing, what is a registration mark used for?

To check that the different colours of ink are aligned correctly with the paper.

What is the function of crop marks on a printed sheet?

They are small lines in each corner that indicate where the paper or board should be cut after printing.

What do colour bars on a printed sheet allow a manufacturer to check?

They serve as a reference chart to check if colours are printed to the correct consistency and intensity.

What is the main commercial printing process for large runs of paper and board products, known for its high and consistent quality?

Offset lithography.

What are the four colours used in the CMYK colour model for offset lithography?

Cyan, magenta, yellow, and key (black).

In the CMYK colour model, why is the letter 'K' used for black?

It stands for 'key', as the cyan, magenta, and yellow printing plates are 'keyed' or aligned with the black plate.

What commercial process is used to accurately cut and crease paper or card at speed, often to produce packaging nets?

Die cutting.

Within a die cutter, what is the difference between sharp blades and rounded blades?

Sharp blades are arranged to produce a cut, while rounded blades are arranged to produce a crease for folding.

What is a 'production aid' in design and technology?

A piece of equipment used to support or simplify the manufacturing process, improving accuracy and efficiency.

The ability to produce the same outcome multiple times without errors is known as __________.

repeatability

What is the main purpose of using a template in manufacturing?

To repeat a 2D outline accurately multiple times by drawing around its shape onto a material.

In casting, what is a solid 'pattern' used to create?

It is used to create a cavity inside another moulding material, such as sand.

What is a 'former' used for in manufacturing?

It is a shape over which a material is bent, pressed, or formed to ensure curves and bends are consistent and repeatable.

What type of production aid would be most suitable for shaping laminated timber sheets into a skateboard deck?

A former.

What is a 'mould' in the context of production aids?

A hollow shape into which a liquid or softened material is poured or pressed to form a complex shape.

What are 'dies' primarily used for with paper and card products?

They are used to cut, press, stamp, or produce embossed (raised) features on products like greeting cards.

What is the key difference between a mould and a die in manufacturing?

A mould is for shaping liquids or softened materials, while a die typically cuts or shapes solid materials through pressure.

What is the function of a 'jig' as a production aid?

A jig is a device that holds a workpiece and also guides a tool, such as a drill or saw, to ensure accuracy and repeatability.

How does a 'fixture' differ from a 'jig'?

A fixture securely holds a workpiece in a specific position, but unlike a jig, it does not guide the tool.

What is the purpose of a 'guide' as a production aid, such as the fence on a bandsaw?

A guide ensures that a tool or material follows a specific, certain path to produce a straight or consistent cut.

What is the purpose of a 'stop' as a production aid, such as the depth stop on a pillar drill?

A stop limits the movement of a tool or material so that parts can be repeatedly cut or drilled to the same length or depth.

Name two production aids commonly used in the manufacturing of timber products.

Templates, jigs, or formers.

Name two production aids commonly used for processing papers and boards.

Dies, templates, or guides.

What is 'finishing' in the context of product manufacturing?

A process that adds a surface treatment to improve how a material looks (aesthetics), feels, or performs (function).

What is the difference between lamination and encapsulation when finishing paper?

Lamination bonds a thin polymer layer to the surface(s) leaving the edges exposed, while encapsulation completely seals the item in plastic, including the edges.

What type of finish is used to protect artwork prone to smudging, like charcoal drawings, and can be applied with a brush or spray?

Varnishing.

Adding decorative details like foil transfer sheets or embossing powders manually to a product is known as _____ ____________.

hand embellishment

What is the small-scale finishing process that uses fine, colored powders that melt when heated to create raised, glossy designs?

Applying embossing powders.

What does 'PPE' stand for in the context of health and safety?

Personal Protective Equipment.

What are VOCs and why are they a health and safety concern when using some finishes?

VOCs (volatile organic compounds) are fumes released by some finishes that can be harmful if inhaled, requiring good ventilation.

What are the three main characteristics of industrial finishing processes?

High speed and volume, quality and consistency, and cost-effectiveness.

What is UV varnishing?

A finishing process where a liquid varnish is applied and then cured instantly with ultraviolet (UV) light to create a high-gloss finish.

What is aqueous coating used for in industrial finishing?

It is a fast-drying, water-based protective layer that adds a light gloss or matte finish while protecting against scuffs and fingerprints.

What is the difference between embossing and debossing?

Embossing creates a raised (sticking out) design on a surface, while debossing creates a sunken or indented (pressed in) effect.

The industrial process of transferring a thin metallic or pigmented foil onto paper using a heated metal die and pressure is called ____ _________.

foil blocking

What high-quality, high-speed printing process involves an image being engraved into a metal cylinder and is ideal for long runs of items like banknotes and passports?

Gravure printing.

What is the printing process that uses flexible rubber or photopolymer plates and is well-suited for printing on uneven surfaces like packaging and labels?

Flexography printing.

What are the three main ways a material's properties can be enhanced?

By combining it with other materials, modifying its structure, or reinforcing it.

In a composite material, what is the role of the 'matrix'?

The matrix is the binder material that holds the reinforcement together.

In a composite material, what is the role of the 'reinforcement'?

The reinforcement is the material added to the matrix to provide strength or other improved properties.

In paper mache, the diluted glue acts as the and the paper fibres act as the .

matrix; reinforcement.

Name one property improved by using foil-lined cardboard for hot food containers.

Thermal insulation or moisture resistance.

What does 'modifying' a material involve?

Changing its internal structure or composition, often at a molecular level, to improve how it performs.

What is the purpose of adding brighteners to paper pulp during production?

To improve the paper's opacity and whiteness.

What is the name of the process that strengthens paper and board by passing it through heated rollers to compress the fibres?

Calendering.

What property of baking paper is achieved by coating it with silicone?

It is made non-stick.

What does 'structural integrity' refer to?

How well a structure or material stays together and holds its shape under stress without breaking.

What is the main purpose of corrugation in cardboard?

To increase its strength and stiffness without adding much weight.

In corrugated cardboard, the wavy paper layer is called the and the flat outer layers are called the .

flute; liners.

What are 'gussets' in paper or card products like bags?

They are additional folded sections that allow the product to expand and improve load distribution, increasing its carrying capacity.

What is the function of interlocking tabs in flat-pack packaging?

They lock into slots to hold the package's shape securely without the need for adhesives, distributing stress across the structure.

What is a 'technical specification' for a product?

A detailed description of a product's requirements and features, such as size, colour, and strength.

A part that is made to the same standard every time so it can be used across a range of different products is called a ___________ ________.

standardised component

What is a major limitation of using visual inspection for quality control?

It may miss hidden or internal faults and its effectiveness relies on the skill of the inspector.

What is the purpose of a GO/NO-GO gauge in quality control?

It provides a quick pass/fail test to check if a dimension is within its specified tolerance.

A part passes a GO/NO-GO gauge test if it fits into the 'GO' side and ____ ____ ___ into the 'NO-GO' side.

does not fit

Which measuring tool is used for very small and precise measurements of thicknesses or diameters?

A micrometer.

In the printing and packaging industries, what tool measures the darkness or density of a printed colour to ensure consistency?

A densitometer.

What is 'sampling' in the context of quality control?

Testing a small, random selection of products from a larger batch instead of checking every single item.

What is a significant disadvantage of using sampling for quality control checks?

Some defective products might be missed in the sample and could reach the customer.

What does 'functional testing' check for in a product?

It checks whether the product performs its intended function as expected, ensuring it is fit for purpose.

What is the key difference between destructive and non-destructive testing (NDT)?

Destructive testing tests a product to its point of failure, wasting the product, while non-destructive testing checks for faults without causing any damage.

Crash testing a car is an example of what type of quality control test?

Destructive testing (DT).

Using X-rays or ultrasound to check for internal flaws in an aircraft component is an example of what type of quality control test?

Non-destructive testing (NDT).

How do automated vision systems perform quality control?

They use cameras to capture images of products and software to automatically check for defects like scratches, misalignment, or colour mismatches.

What is one major advantage of automated inspection systems over human visual inspection?

They are faster, more reliable, can detect tiny variations, and can inspect every product on a high-speed production line.

A greeting card has a specified length of 195 mm with a tolerance of +/- 1 mm. What is the acceptable range of lengths?

The acceptable range is from 194 mm to 196 mm.

In offset lithography, ink is transferred from a metal plate to a _____ ______ before being applied to the paper.

rubber roller

What is a 'net' in the context of die-cut packaging?

A flat shape which can be cut out and folded to make a 3D solid shape, like a box.

The industrial printing process works on the principle that oil and _______ do not mix.

water

What production aid is most commonly used to cut fabric into the correct shape for garments?

A pattern.

What is the purpose of adding a polyethylene (PE) coating to paper in industrial finishing?

To provide moisture and grease resistance.

An industrial finishing process where a heated roller bonds a thin film to paper to create a gloss, matte, or soft-touch finish is called _________ _________.

industrial lamination

Why is die cutting a suitable process for mass production?

It can accurately cut and crease materials at high speed, ensuring consistency across many identical items.

In food production, QC ensures products are correctly weighed and free from ____________.

contamination

In the automotive industry, what quality control method is essential for checking safety and durability in a crash?

Destructive testing.

Why are standardised components like bolts and fittings crucial in the construction industry?

They ensure structural safety and reliability through consistent quality and dimensions.

What is a significant risk of using batch sampling for medical devices?

A defective item could be missed and subsequently cause harm to a patient.

Which is generally a quicker but less precise quality control check: a GO/NO-GO gauge or a micrometer?

A GO/NO-GO gauge.

The use of automated inspection is expensive to install and maintain but is often justified for ____________ manufacturing.

high-precision

What is ribbing, as seen on the inside of some packaging boxes?

Internal walls designed to provide extra support to items by reducing movement and adding strength.