Design Production: Finishing

Die cutting is a manufacturing process used to generate large numbers of the same shape from a material such as wood, plastic, metal, or fabric. The die cut shapes are sometimes called “blanks,” because they are usually finished and decorated before being sold. The process is widely used on an assortment of materials all over the world, and many manufactured products contain several die cut components, often assembled together in a series of steps to create a finished product.

Sharp specially shaped blades are used in die cutting. The blade is bent into the desired shape and mounted to a strong backing. The result is known as a die. The material being cut is placed on a flat surface with a supportive backing, and the die is pressed onto the material to cut it. Depending on what is being made, a single die might cut one piece of material, or it might be designed to slice through multiple layers, generating a stack of blanks.

Many consumers find it helpful to consider a cookie cutter when thinking about die cutting. The cookie cutter is a type of die which is capable of cutting out a potentially infinite amount of blanks. Each blank will be exactly the same shape and size, meaning that the blanks can be cooked uniformly together and decorated at will for individuality. The alternative is cutting out each cookie by hand, a painstaking process which would result in irregular final products.

Creating dies is meticulous work. The die must be designed so that it efficiently cuts the desired material with minimal waste. Most factories which use die cutting as part of their manufacturing process have techniques for recycling material left over from die cutting, but they want to avoid excess if possible. Often, multiple dies are fitted together on one mount, nestled with each other for maximum efficiency. Material left over from the die cutting process may be melted down and reused, or reworked into other components.

Common examples of die cut items include keys, paper products, and flat plastic pieces which can be snapped together. Die cutting is limited, because it can only really be used to produce flat objects. For more dimensional shapes, other manufacturing techniques such as molds need to employed. Dies can also range widely in size from cookie cutters to massive machines designed to cut out ship components. With large dies, it is important to observe safety precautions whiledie cutting, as an industrial die designed to slice through metal can also remove a limb without difficulty.

http://www.wisegeek.com/what-is-die-cutting.htm

3 ring binder

This kind of binding is rarely used. And if used, it’s usually used for binding of notes together.

Case binding

Case binding is used in hardcover books. The spine of the book are sewn, glued, and added with gauze cloth before binding them in the case binding machine.

Perfect binding or Thermal binding

Thermal binding (hot tape binding) is often called perfect binding. It is well suited for thick books and thick magazines. Thermal binding uses heat and glue to bind the book together.

Plastic comb binding or spiral-o binding

It is one of the most common binding forms. Plastic combs are used to hold the adjoining pages together. Similar to a spiral binding, the difference is in the material used. It looks like a notebook with wire binding except that plastic comb is used to hold the pages together. This form of binding allows the pages to be opened flat. The material can be removed and reattached as needed.

Saddle stitching

This kind of binding is usually used in thin comic books and news magazines. The pages are joined together and are stapled in the middle to hold them together. It is the most widely used binding method because of its simplicity and economical method.

Spiral binding

It is sometimes called coil binding or plastic wire binding. It depends on the material used. Spiral binding may use plastic wire, coil, or wire to hold the papers together. It is used in notebooks all of the time. A perfect example of spiral binding is the binding of spiral notebooks. This type of binding allows the document to be opened flat.

Stapled binding

Not a very common binding type. It is also known as side stitch binding. The binding together of the document are not done in the middle or the spine of the book but are stapled at the sides. This kind of binding looks very informal and is more appropriate for unofficial documents.

Tape binding

As the name implies, tape binding uses tape to bind the book together. It is sometimes called cold tape binding. Tape binding places a cloth strip of adhesive tape to hold the pages together.

Twin loop wire

Twin loop wire is similar to spiral binding. Wires are used to bind the book together. This is used in some notebooks to hold the pages together. This type of binding is very durable and allows the pages to be opened flat.

Velo binding

Velo binding looks like a perfect bound book. That is because this type of binding is also perfect. It is usually used by lawyers for their documents. Velo binding uses heat, glue, hot knife, and plastic strips during its binding process.

http://beatsme.hubpages.com/hub/The-Different-Book-Binding-Types#

Saddle Stitching (Saddle Wire / Stitch Trim)

Definition: Saddle Stitching is a method of binding one or more printed sections together, with or without a cover, by means of wire staples (stitches) through the spine and centrefold. Otherwise known as Booklet Making or Stitched.

What is it used for? Commonly used for Brochures, Annual Reports, Booklets, Newsletters, Price Lists, Catalogues, Parish Plans, Town Plans

At What Point do we do it? Saddle Stitching is a print finishing process (after printing).

How do we do it? Our Stitch Trimming machine will inset (gather) sections, stitch with the number and type of wire required and trim on 3 edges to the finished size.

More about... We can saddle stitch with up to 4 stitches (wires). Endorse Folding (folding in half after stitching) is possible by using our mobile knife unit, enabling thin products to be folded in half after stitching and trimming.

Loop Stitching (Loop stitch 2 wires, loop stitch 4 wires)

Definition: Loop Stitching is a method of binding one or more printed sections together, with or without a cover, by means of loop wire staples (stitches) through the spine and centrefold. The loops enable the printed item to be inserted into a Ring Binder

What is it used for? Commonly used for Brochures, Price Lists, Catalogues, Booklets, Newsletters, Parish Plans, Town Plans where they need to be inserted into 2 or 4 ring Ring Binders

At What Point do we do it? Loop Stitching is a print finishing process (after printing).

How do we do it? Our Stitch Trimming machine will inset (gather) sections, stitch with the number and type of wire required and trim on 3 edges to the finished size.

More about... We can Loop stitch with up to 4 stitches (wires).

Perfect Binding

Definition: Perfect Binding is a method for binding printed sheets suitable for binding documents where they are too thick to saddle stitch. Perfect Binding is most commonly used on paperback books.

What is it used for? Commonly used for Price Lists, Magazines, Brochures, Catalogues, PLOF, Books, Parish Plans, Town Plans

At What Point do we do it? Perfect Binding is a print finishing process (after printing).

How do we do it? The pages and printed sections are gathered in order, spine milled (the spine is ground to provide a key), and held together with a hot melt adhesive. A cover (usually on a heavier paper weight) is attached to the spine and is formed around the book.

More about... The minimum thickness of a perfect bound print job is approx 3mm (around 48pp). The maximum thickness is 50mm.

PUR Binding

PUR binding is very similar to perfect binding. But uses a more durable and flexible glue. It is nearly impossible to remove pages from a PUR Bound book, and the spine doesn't deteriorate with age. Ideal for printed items that need to be durable reference tools - Catalogues, price lists, prospectus, brochures, town plans, parish plans etc

Sewn with Drawn on Cover

Definition: This method of binding is very similar to perfect binding. However, the sections are gathered in order, sewn together using thread, adhesive applied to the sewn spine, and the cover attached (drawn on) and formed around the book.

What is it used for? Ideal for printed items that need to be durable reference tools - Price Lists, Books, Prospectus, Brochures, Town Plans, Parish Plans etc

At What Point do we do it? Sewn Binding is a print finishing process (after printing).

How do we do it? This method of binding is very similar to perfect binding. But uses a more durable and flexible glue. It is nearly impossible to remove pages from a PUR Bound book, and the spine doesn't deteriorate with age. Ideal for printed items that need to be durable reference tools - Price Lists, Prospectus, Brochures, Town Plans, Parish Plans etc

Stab Stitching

Definition: Stab Stitching is used mainly for office documents and in essence is two or more very strong, long staples that bind together loose sheets up to 25mm thick.

What is it used for? Commonly used for Office stationery eg. NCR Pads, Purchase Order Pads, Invoice Pads, Sales Order Forms etc

At What Point do we do it? Stab Stitching is a print finishing process (after printing).

How do we do it? Loose sheets are collated, usually with a grey backboard and Manila top sheet, they are stab stitched with our stab stitching machine approx 8mm from the edge and to ensure the item is secure and presentable we then apply calico tape to the spine.

Corner Stitch

Definition: A method for binding loose sheets suitable for documents up to 3mm thick.

What is it used for? Commonly used for hand outs, proposal documents etc

At What Point do we do it? Corner Stitching is a print finishing process (after printing).

How do we do it? The pages are collated in order and a single wire stitch (staple) is used to secure the document in the corner.

Wiro Binding

Definition: A method for binding loose leaves using a series of metal wire loops formed from a single continuous wire run through punched holes on the binding edge.

What is it used for? Commonly used for Price Lists, PLOF, Training Manuals, Calendars, Note Pads, Parish Plans, Town Plans

At What Point do we do it? Wiro Binding is a print finishing process (after printing).

How do we do it? The pages are gathered in order, punched, and the metal wiro spine is inserted and clenched.

More about... Wiro Binding allows the book to lie flat and is such is well suited to the production of manuals.

Spiral Binding

Similar to Wiro Binding, Spiral Binding attached the loose sheets by means of a plastic or metal plastic coil being passed through the punched holes. A wide range of coloured coils are available. Most commonly used for the production of very thick price lists, road atlases, reference manuals and training manuals. Pages from spiral bound documents cannot come undone from the binding.

Comb Binding

Again very similar to wiro binding, but instead uses a plastic comb instead of a wire. Mainly used for office documents.

Binding Screws

Definition: Used for binding loose sheets, pillar and post screws are used to secure the printed document.

What is it used for? Commonly used for product swatches, photo albums, bespoke brochures etc

At What Point do we do it? Binding Screws are a print finishing process (after printing).

How do we do it? The pages are gathered in order, drilled, and the pillars and posts are inserted until they meet - they are secure by screwing the pillar and post together..

More about... Interscrews are available in Brass, Nickel, Black or White Plastic. Available heights for book thicknesses are 2, 3.5, 6, 10, 12, 16, 20, and 25mm.