Paper and board processes

These notes follow the teacher revision material, keeping the process sequences detailed but concise.

Die cutting and creasing

What it is: A steel-rule die cuts repeated profiles/nets while creasing rules compress the material to create accurate fold lines without cutting through it.

Step by step

Position the paper or board accurately on the cutting bed so the printed design and required cut/crease lines are correctly registered.
Align the cutting die, which contains sharpened cutting rules and lower creasing rules arranged to match the required net/profile.
Close the press and apply controlled pressure so the cutting rules pass through the material while the creasing rules compress the fibres along the fold lines.
Open the press, remove the cut component and separate the surrounding waste material.
Check that all cuts are complete, crease lines are correctly positioned and the finished component matches the required dimensions.

Common uses: packaging nets, cartons and repeated paper/card profiles.

Advantages: cutting and creasing can be completed in one operation; fast and repeatable for larger quantities.

Disadvantages: a dedicated die must be produced, creating setup/tooling cost and making it less suitable for very small quantities.

Quality control: check registration, cutting-rule sharpness, crease depth, complete cuts, fold position and dimensional consistency.

Safety: cutting, crushing and finger-trapping hazards around the press; guards and correct operating procedures are required.

Folding / bending

What it is: Paper or board is folded accurately along a crease where the fibres have been compressed to allow a clean bend.

Step by step

Mark or align the required fold line and position the sheet accurately in the creasing equipment.
Select a suitable creasing rule/wheel for the thickness of the paper or board.
Apply controlled pressure along the line so the fibres are compressed without cutting through the material.
Fold the material accurately along the prepared crease, using the crease to control the position and direction of the bend.
Check the finished fold for correct alignment, consistent angle and any cracking or damage to the printed surface.

Common uses: boxes, cartons, folders and packaging.

Advantages: produces clean, controlled and repeatable folds.

Disadvantages: incorrect crease depth or unsuitable material can cause cracking or fibre damage.

Quality control: check fold alignment, crease depth and consistency and make sure the surface has not cracked.

Safety: powered creasing/folding equipment creates finger-trap and crushing hazards; use guards and keep hands clear.

Laser cutting

What it is: A CNC-controlled laser follows digital CAD/CAM data to cut or engrave paper and board accurately without a physical cutting die.

Step by step

Create or load the required CAD/CAM file, checking the design, dimensions and scale before machining.
Place the paper or board flat on the laser bed and secure it where required so it cannot move during cutting.
Focus the laser and set the correct power and speed for the type and thickness of material.
Run the programmed cutting/engraving path with the enclosure closed and extraction operating to remove smoke and fumes.
When the machine has finished and it is safe to open, remove the component and check dimensions, edge quality and any scorching/burn marks.

Common uses: decorative card, prototypes, model making and customised packaging.

Advantages: accurate complex shapes can be produced directly from digital data; designs are easy to change and no physical cutting die is required.

Disadvantages: less economical than dedicated die cutting for very high repeated quantities; incorrect settings can scorch or burn the material.

Quality control: check CAD scale, material position, laser focus, power/speed settings, cut dimensions, kerf and burn marks.

Safety: extraction is essential because paper/board produces smoke; there is a fire risk and the laser must never be viewed directly.