Die cutting is the process of using a die to shear webs of low strength materials, such as rubber, fibre, foil, cloth, paper, corrugated fibreboard, paperboard, plastics, pressure sensitive adhesive tapes, foam and sheet metal. In the metalworking and leather industries, the process is known as clicking and the machine may be referred to as aclicking machine. When a dinking die or dinking machine is used, the process is known as dinking. Commonly produced items using this process include gaskets, labels, corrugated boxes, and envelopes.
Die cutting started as a process of cutting leather for the shoe industry in the mid-19th century. It is now sophisticated enough to cut through just one layer of a laminate, so it is now used on labels, stamps, and other stickers; this type of die cutting is known askiss cutting.
Die cutting can be done on either flatbed or rotary presses. Rotary die cutting is often done inline with printing. The primary difference between rotary die cutting and flatbed die cutting is that the flatbed is not as fast but the tools are cheaper. This process lends itself to smaller production runs where it is not as easy to absorb the added cost of a rotary dieBinding
There is no way to be certain where book crafting originated; it was an evolving art encompassing techniques from a variety of cultures and civilizations.
The craft of bookbinding probably originated in India, where religious sutras were copied on to palm leaves (cut into two, lengthwise) with a metal stylus. The leaf was then dried and rubbed with ink, which would form a stain in the wound. The finished leaves were given numbers, and two long twines were threaded through each end through wooden boards, making a palm-leaf book. When the book was closed, the excess twine would be wrapped around the boards to protect the manuscript leaves. Buddhist monks took the idea through Persia, Afghanistan, and Iran, to China in the first century BC.
Methods of hardcover binding
There are a number of methods used to bind hardcover books, from them:
- Case binding is the most common type of hardcover binding for books. The pages are arranged in signatures and glued together into a "textblock.". The textblock is then attached to the cover or "case" which is made of cardboard covered with paper, cloth, vinyl or leather. This is also known as perfect binding, cloth binding, or edition binding.
- Oversewing, where the signatures of the book start off as loose pages which are then clamped together. Small vertical holes are punched through the far left-hand edge of each signature, and then the signatures are sewn together with lock-stitches to form the text block. Oversewing is a very strong method of binding and can be done on books up to five inches thick. However, the margins of oversewn books are reduced and the pages will not lie flat when opened.
- Sewing through the fold (also called Smyth sewn), where the signatures of the book are folded and stitched through the fold. The signatures are then sewn or glued together at the spine to form a text block. In contrast to oversewing, through-the-fold books have wide margins and can open completely flat. However, the text block of a sewn-through-the-fold book is not very secure, which can cause some signatures to come loose over time. Many varieties of sewing stitches exist, from basic links to complex decorative stitches. While Western books are generally sewn through holes punched along the fold, some Asian bindings, such as the Retchoso or Butterfly Stitch of Japan, use small slits instead of punched holes.
- Double-fan adhesive binding starts off with two signatures of loose pages, which are run over a roller—"fanning" the pages—to apply a thin layer of glue to each page edge. Then the two signatures are perfectly aligned to form a text block, and glue edges of the text block are attached to a piece of cloth lining to form the spine. Double-fan adhesive bound books can open completely flat and have a wide margin. However, certain types of paper do not hold adhesive well, and, with wear and tear, the pages can come loose.[14]
Double wire, twin loop, or Wire-O binding is a type of binding that is used for books that will be viewed or read in an office or home type environment. The binding involves the use of a "C" shaped wire spine that is squeezed into a round shape using a wire closing device. Double wire binding allows books to have smooth crossover and is affordable in many colors. This binding is great for annual reports, owners manuals and software manuals. Wire bound books are made of individual sheets, each punched with a line of round or square holes on the binding edge. This type of binding uses either a 3:1 pitch hole pattern with three holes per inch or a 2:1 pitch hole pattern with two holes per inch. The three to one hole pattern is used for smaller books that are up to 9/16" in diameter while the 2:1 pattern is normally used for thicker books as the holes are slightly bigger to accommodate slightly thicker, stronger wire. Once punched, the back cover is then placed on to the front cover ready for the wire binding elements (double loop wire) to be inserted. The wire is then placed through the holes. The next step involves the binder holding the book by its pages and inserting the wire into a "closer" which is basically a vise that crimps the wire closed and into its round shape. The back page can then be turned back to its correct position, thus hiding the spine of the book.
Different types of the punch and bind binding include:
- Comb binding uses a 9/16" pitch rectangular hole pattern punched near the bound edge. A curled plastic "comb" is fed through the slits to hold the sheets together. Comb binding allows a book to be disassembled and reassembled by hand without damage. Comb supplies are typically available in a wide range of colors and diameters. The supplies themselves can be re-used or recycled. In the United States, comb binding is often referred to as 19-ring binding because it uses a total of 19 holes along the 11-inch side of a sheet of paper.
- VeloBind is used to permanently rivet pages together using a plastic strip on the front and back of the document. Sheets for the document are punched with a line of holes near the bound edge. A series of pins attached to a plastic strip called a Comb feeds through the holes to the other side and then goes through another plastic strip called the receiving strip. The excess portion of the pins is cut off and the plastic heat-sealed to create a relatively flat bind method. VeloBind provides a more permanent bind than comb-binding, but is primarily used for business and legal presentations and small publications.
- Spiral binding is the most economical form of mechanical binding when using plastic or metal. It is commonly used for atlases and other publications where it is necessary or desirable to be able to open the publication back on itself without breaking the spine. There are several types but basically it is made by punching holes along the entire length of the spine of the page and winding a wire helix (like a spring) through the holes to provide a fully flexible hinge at the spine. Spiral coil binding uses a number of different hole patterns for binding documents. The most common hole pattern used with this style is 4:1 pitch (4 holes per inch). However, spiral coil spines are also available for use with 3:1 pitch, 5:1 pitch and 0.400-hole patterns.
- Proclick (GBC) is a relatively new binding style that was originally designed for use with a 3:1 pitch wire binding hole pattern. This type of binding uses an element that snaps shut and can be easily opened for editing purposes. The editing abilities of this style make it popular with direct sales organizations and mobile offices. Proclick is manufactured exclusively by the General Binding Corporation.
- ZipBind is also manufactured by the General Binding Corporation and offers easy editing. However, the binding spines for this style are designed to work with the 9/16" plastic comb binding hole pattern. Like Proclick, Zipbind spines can easily be opened and closed without the need for a binding machine. Thus the addition and deletion of pages is a simple process provided that the pages have already been punched.
Some of the different types of thermally activated binding include:
- Perfect binding is often used, and gives a result similar to paperback books. National Geographic is one example of this type. Paperback or soft cover books are also normally bound using perfect binding. They usually consist of various sections with a cover made from heavier paper, glued together at the spine with a strong flexible glue. The sections are rough-cut in the back to make them absorb the hot glue. The other three sides are then face trimmed. This is what allows the magazine or paperback book to be opened. Mass market paperbacks (pulp paperbacks) are small (16mo size), cheaply made with each sheet fully cut and glued at the spine; these are likely to fall apart or lose sheets after much handling or several years. Trade paperbacks are more sturdily made, with traditional gatherings or sections of bifolios, usually larger, and more expensive. The difference between the two can usually easily be seen by looking for the sections in the top or bottom sides of the book.
- Thermal binding uses a one piece cover with glue down the spine to quickly and easily bind documents without the need for punching. Individuals usually purchase "thermal covers" or "therm-a-bind covers" which are usually made to fit a standard size sheet of paper and come with a glue channel down the spine. The paper is placed in the cover, heated in a machine (basically a griddle), and when the glue cools, it adheres the paper to the spine. Thermal glue strips can also be purchased separately for individuals that wish to use customized/original covers. However, creating documents using thermal binding glue strips can be a tedious process which requires a scoring device and a large format printer.
- A cardboard article looks like a hardbound book at first sight, but it is really a paperback with hard covers. Many books that are sold ashardcover are actually of this type. The Modern Library series is an example. This type of document is usually bound with thermal adhesive glue using a perfect binding machine.
- Tape binding refers to a system that wraps and glues a piece of tape around the base of the document. A tape binding machine such as the Powis Parker Fastback or Standard Accubind system will usually be used to complete the binding process and to activate the thermal adhesive on the glue strip. However, some users also refer to Tape Binding as the process of adding a colored tape to the edge of a mechanically fastened (stapled or stitched) document.
- Unibind is a variety of thermal binding that uses a special steel channel with resin rather than glue inside of it to give it a more sturdy bind to hold the pages in place. Unibind can be used to bind soft covered documents with a look that is similar to perfect binding. It can also be used for binding hardcover books and photo books. Like Thermal Binding, unibind usually requires you to purchase a one piece coverset to bind your documents. However, Unibind also offers SteelBack spines that allow you to use your own covers in the binding process. The majority of Unibinds covers can be printed on as well to give documents a unique finish. (Unibind is also the name of an International binding company)
Types of stitched or sewn bindings:
- A sewn book is constructed in the same way as a hardbound book, except that it lacks the hard covers. The binding is as durable as that of a hardbound book.
- Stapling through the centrefold, also called saddle-stitching, joins a set of nested folios into a single magazine issue; most American comic books are well-known examples of this type.
- Magazines are considered more ephemeral than books, and less durable means of binding them are usual. In general, the cover papers of magazines will be the same as the inner pages (self-cover) or only slightly heavier (plus cover). Most magazines are stapled or saddle-stitched; however, some are bound with perfect binding and use thermally activated adhesive.
Book folding
Book folding is the stage of the book production process in which the pages of the book are folded after printing and before binding.
Until the middle of the 19th century, book folding was done by hand, and was a trade. In the 1880s and 1890s, book folding machines by Brown and Dexter came onto the market, and by the 1910s hand-folding was rare, with one publisher declaring them to be "practically obsolete" in 1914.
The folding process is also necessary to produce print products other than books--for instance mailings, magazines, leaflets etc.
Buckle folder
In a buckle folder, the paper is first passed through 2 spinning rollers, which feed the paper into a pair of guide plates that redirect the paper at a slight angle, bending the paper. At the far end of the guide plates is a "paper stop". As the rollers continue to spin, the paper continues to slide in between the guides until it hits the paper stop, then, having nowhere else to go, buckles at the interface between the rollers and the angled guides. As the rollers continue to spin, the buckle increases, until it is eventually caught by a pair of "nip" rollers, which pull the buckle in and compresses and flattens it into a neat crease.
Adjusting the paper stop in a buckle folder determines where the fold will be placed. Also, a buckle folder may contain only 3 rollers, with one shared by both the input rollers and the nip rollers.
Knife folder
Although buckle folders are fast, simple, efficient, and have small folding tolerances, they are not suitable for substrate of very low (<40g/m²) or very heavy paper grammage (>120g/m²).In a knife folder, a sheet of paper is fed horizontally over 2 unpowered rollers until it hits a paper stop, at which point a dull blade pushes down on the paper and in between the 2 rollers to create the fold.
Although the knife folder is slower than buckle folders, it is more precise and can handle extreme grammages very well. It also has small folding tolerances, but is a more complex machine.
Folding a paper more than once in the same direction (i.e. with parallel creases) is calledparallel folding. Common examples of this are the half fold, letter fold, gate fold, andZ-fold.
Cross folds
A cross fold is when a paper is folded once, then rotated 90 degrees and folded again. The creases therefore cross each other at right angles. The most basic cross fold is theFrench fold, or right-angle fold. Other examples include the 16-page broadside and the 12-page letter.
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