Processes: Papers, Cards & Boards

Paper and Board Forming Processes

Introduction

• Paper and board are increasingly used in product design and manufacturing as replacements for less sustainable materials like polymers.
• It's important to understand how paper and board are formed into 3D products using methods like die cutting and creasing, laser cutting, and bending.

Die Cutting and Creasing

• Die cutters create paper or card 'nets' or 'developments' that, when folded and assembled, form 3D shapes (e.g., boxes).
• Die cutters use a plywood 'substrate' board into which steel cutting dies and creasing rules are inserted.
• The stock material is placed under the board, and a press pushes the board into the stock material, cutting out the net.
• Creasing rules score the paper or card where folds are needed. They are shorter and blunter than cutting dies.

Components of a Die Cutting Machine:

• Plywood substrate: the base of the die cutter into which the cutting and creasing rules are inserted.
• Steel cutting dies: Sharp blades that cut the outline of the net.
• Creasing rules: Blunt blades that score the material to create a folding line.
• Creasing channels: Raised part on the machine bed that works with the creasing rule to create a bending line.
• Press: Applies pressure to push the plywood substrate into the sheet material.
• Ejection rubber: Prevents the paper or card from sticking to the press.

The Die Cutting Process:

1. A plywood substrate is prepared with steel cutting dies and creasing rules inserted.
2. The sheet material (paper or card) is placed under the substrate.
3. A press applies pressure, pushing the substrate into the sheet material.
4. The cutting dies cut the outline of the net, while the creasing rules score the material for folding.
5. Creasing channels on the machine bed help create the bending lines.
6. Rubber pads prevent the paper or card from sticking to the press.

Bending

• The stamped-out net is placed onto a folding table.
• Some die cutting presses have moving parts that automatically bend or fold parts of the net.
• For example, when making boxes, the die-cut net is held firmly while the sides of the box are bent up along the crease lines.
• Some of the more difficult finishing may be done by hand.
• In industry, larger machines may perform die cutting, creasing, and folding in one process.

Laser Cutting

• Laser cutters are suitable for prototype construction or small-scale production.
• They can cut, engrave, perforate, and carve various materials.
• Laser cutting is becoming common in packaging production for prototypes and small batches due to its speed, accuracy, and high level of detail.
• Lasers are flexible, allowing for quick changes in designs without the need for a new die board. 2D drawings can be downloaded and cut rapidly.
• Laser cutting can process paper, cardboard, corrugated card, and polymer film.