Lesson video

Hello, thank you for joining me for your design and technology lesson.

My name is Mrs. Conway, and I will be guiding you through the learning for this lesson today.

So our lesson outcome for today, then, is: "I can explain and compare small-scale and industrial deforming processes." And our keywords, then, are: "deform," "force," "automation," and "emboss." And I'll go through each one of these in a little bit more detail as they come up throughout the lesson.

So, first of all then, we're going to start by looking at small-scale deforming processes.

Now, a deforming process changes the shape of a material without removing any parts, and it does this by using a force to shape paper and boards into a new form.

Deforming paper and boards makes it easier to create three-dimensional shapes that would be normally challenging to cut directly.

So, for example, we have a cupcake case here and also a quilled paper lion.

So deforming has been used to make these.

Okay, quick check for understanding on that, then.

What is a deforming process in manufacturing? Is it A, cutting materials; B, joining materials; C, changing shape by force without removing material; or D, adding a coating? Pause the video here and just take a moment to think about your answer.

And the correct answer? It was changing shape by force.

So the deforming process changes shape by force without removing any material.

Well done if you got that right.

So, small-scale deforming processes often use quite simple, manual tools.

And when folding paper and boards by hand, simple manual tools can be used, like a bone folder, rulers, and also scissors.

Bone folders are used to apply force along the fold line for accuracy.

And this is an example of a bone folder.

Now, marking out and then using a tool, like a pair of closed scissors, for example, to score the paper or board is another small-scale deforming process to achieve a fold by hand.

Now, a variety of tools can be used to score paper and boards, as long as it is completed safely.

So, if we actually have a look at this process, then, we do the marking out; and we've got a steel rule there, and we've used a pencil to mark out where that line's going to be.

And then we can do safe scoring with a closed pair of scissors, and we follow along the edge of the steel rule to do this.

And we can also see that we're using a safety rule, especially, and a safety rule allows for those fingers to be sunken into the middle of the ruler and kept out of harm's way.

And if we use that scoring technique, then what we can do is create a score to help create a much neater fold.

Embossing is a printing technique that creates a raised design or pattern on paper or board by pressing them with a tool like a stamp.

Now, simple manual tools for embossing include a stylus with a variety of different-sized and shaped nibs, such as soft mats, stamps, mallets, and hammers.

So this is an example of an embossing stylus, and we can create hand-embossed lines using these stylus tools.

We can also, however, use the mallet and stamps as well.

Okay, quick check for understanding on embossing, then.

Just have a go at filling out the missing word.

Embossing is a printing technique that creates a "something" design.

Pause the video here just to have a think about what that missing word could be.

Okay, and the missing word, it was raised.

So embossing is a printing technique that creates a raised design.

Small-scale embossing can include manufacturing a handmade die.

The die below was made using duplex board, and layers of the board have been peeled away, whilst others have had a texture added using tissue paper.

And the yellow-brown finish is a shellac finish to stop the die from sticking to the card when being embossed.

So this is an example of a handmade embossing die.

And when it's used, this is the outcome.

Constructing a paper or card net is a way of deforming the material as well.

Now, this is only possible due to the crease or fold lines produced onto the net, and this can be done by hand or using a die-cutting press.

So this is a die for a paper or card packaging net.

You can see there are cut lines there, and also the crease or fold lines are included as well.

Okay, quick check for understanding, then.

I'd like you to have a look at this picture, and I just showed you it on the previous slide.

On it, I'd like you to identify the cut and crease fold lines on the die image.

Just pause the video here to have a go at this.

Okay, how did you get on? Right, so the crease or fold lines are the ones that are in the middle, and they are kind of not as obvious.

You can just about see them; they're a little bit fainter, whereas the cut lines are a little bit clearer to see, and those are around the edges on this example.

Crimping paper and boards is the process of deforming the material to produce a wavy, zigzag texture.

Now, it's created by pressing it through rollers with ridges.

And this crimped texture adds strength, flexibility, and also a decorative element.

And it's commonly used for packaging, crafts, and cushioning materials.

So this is an example of crimped packaging paper, and you may have seen some of this in packaging that you've received when you've received something through the post.

And this is an example of a small-scale crimping tool.

Quilling is a deforming paper craft technique that involves rolling, shaping, and glueing thin strips of paper to create decorative designs.

So this is an example of different quilling shapes that can be made.

And you can see there is a variety of different shapes that can be made using different techniques.

And obviously, this takes a little bit of practise to do.

Quilling is often used to make intricate patterns for cards, wall art, and other creative projects.

As you can see, this example here of a piece of wall art of a quilled fish, the detail of this is quite immense.

It's incredibly intricate in its design.

And this has been created using a slotted tool.

And hopefully, in this example, you can see the end of the slotted tool has the paper wrapped around it.

And you can see there's a little tiny bit of glue, possibly PVA glue, at the end of that, just to kind of hold that in place once it's been kind of twirled round.

Now, with small-scale deforming processes, there are benefits and limitations.

So with small-scale deforming processes, they are low cost and easy to set up, and they're really good for any one-off prototype pieces.

They can also, just like you saw in the example of that fish, can achieve detailed and bespoke shapes.

However, there are, of course, limitations.

So they can be time-consuming if we compare them to industrial methods, and they do require skill and also patience.

If you can imagine the skill and patience that went into that example of the fish I showed you.

And of course, they're also limited to smaller or thinner paper and boards as well.

Okay, quick check for understanding here, then.

Which of the following is a limitation of small-scale deforming processes? A, time-consuming; B, can achieve bespoke shapes; C, low cost; or D, good for prototypes? Pause the video here, just take a moment to think about your answer.

And the correct answer, that limitation is time-consuming.

All the others are actually advantages to doing small-scale deforming processes, but the limitation is that they can be quite time-consuming.

Okay, it's going to be over to you now to have a go at some tasks.

The first thing I'd like you to do, then, is to explain what is meant by a deforming process in paper and board product manufacturing.

The second thing I'd like you to do is to draw a diagram of a simple cardboard net, and I'd like you to label the crease fold lines as well as the cut lines on that diagram.

I'd then like you to describe small-scale embossing by hand, and in that, I'd like you to include the different types of tools and equipment that are used for that process.

And lastly, I'd like you to give two benefits and two limitations of small-scale paper and board deforming processes.

Okay, pause the video here to have a go at these four different tasks, and good luck.

Okay, hopefully you got on okay with all of those four tasks.

We're gonna go through each one in detail now with some example answers.

So the first thing I asked you to do was to explain what is meant by a deforming process in paper and board product manufacturing.

So, the example answer says this: "A deforming process changes the shape of a paper or board without cutting away any material.

It uses force to shape the material into a new form.

Just check that answer against yours and see if you've got all the key points included.

The next thing I asked you to do, then, was to draw a diagram of a die for die-cutting a simple cardboard net.

And I asked you to also label the crease fold lines and the cut lines.

Now, here's an example of a simple net.

You may have drawn one slightly differently.

That's fine.

But just check that you've got the right places for the cut lines and also the crease fold lines, as with the example here.

The third thing I asked you to do, then, was to describe small-scale embossing by hand.

And I asked you to include the different types of tools and equipment in this.

So, let's look at an example answer, then.

Embossing is a printing technique that creates a raised design or pattern on paper or boards by pressing them with a tool like a stamp.

Other tools include stylus, soft mats, mallets, and hammers.

Again, just check that you've actually described the actual embossing and also explained the tools and equipment that are needed in there as well.

And lastly, I asked you to give two benefits and two limitations of small-scale paper and boards deforming processes.

The benefits you could have mentioned here: low cost and easy to set up, good for creating custom or prototype pieces.

And the example answer the limitations that have been included are time-consuming and requires skill, limited to smaller or thinner paper and boards.

There were some other examples that you might have put in there, but these are just two examples that have included in this example answer.

Okay, let's move on then.

So next we're gonna look at industrial deforming processes.

So we've looked at small scale; we now want to look at it on an industrial level.

Now, industrial paper and board deforming processes are used in large-scale manufacturing to increase things such as speed.

The machines can work continuously in large-scale processing, and that means that they can work quickly with minimal downtime.

It also helps to improve accuracy as well.

So things such as CNC, which is your computer numerical control, those machine systems produce highly consistent shapes.

And also then that word "consistency," every product matches the design exactly.

And that's really ideal for higher-volume production, and that can be because of things such as the CNC machines.

Okay, quick check for understanding on that then.

What is one key benefit of using industrial deforming processes over small-scale ones? A, they require more human input.

B, they provide faster and more consistent results.

C, they use less electricity.

D, they are more random in shape.

Pause the video and just have a quick think about your answer.

And the correct answer then was B.

So a real big benefit of industrial deforming processes over small-scale ones is that they provide faster and more consistent results.

Well done if you got that right.

Now, formers are a tool over which material can be formed, and they do this using force.

Sometimes formers come in two parts: a negative and a positive.

Now, the negative former part is a hollow shape that the material forms into, and the positive former part is a raised shape the material forms over.

So if you imagine a sheet of board in between these two moulds, or these two forms, when these are pressed together, that piece of board is going to follow and fall into the negative shape and be pushed into it by the positive shape.

Now, industrial embossing creates raised designs on materials.

A material is pressed between a negative and positive former under a controlled force, and also sometimes heat is applied as well.

Embossing can be done with rollers that have a raised surface design.

Now the paperboard is fed through the rollers, and the design is pressed onto the material.

So here we have that example that I just showed you before, the positive and negative former, and they are currently apart, and you've got that sheet material in between.

Now, heat and pressure are then applied.

The pressure is applied by forcing the two formers together, and you've got some heat being applied at the same time.

When the formers are then pulled apart, your material has then formed to that shape.

Now, embossing is used to add texture, decoration, lettering, branding, or functional features as well, like a grip to a product, for example.

Common applications include packaging, stationery, book sleeves, textiles, and product labelling.

And you may have seen these on things like stationery and books previously.

This is an example of paper embossing.

Industrial braille embossing is a process used to create raised braille dots on packaging, labels, or printed materials to make information accessible for visually impaired users.

And you may have heard of braille before.

Now, it involves pressing or stamping materials with a precise embossing die that forms braille characters.

So this is an example of a braille embosser, and these are the outcomes.

These are the braille dots that have been embossed.

Quick check for understanding then.

The technique used to raise the lettering on this book sleeve is called: A, bebossing; B, rebossing; C, debossing; or D, embossing? Pause the video here just to think about your answer.

And the correct answer was D.

Okay, so this is an example of embossing.

Industrial die cutting and creasing is a manufacturing process used to cut and fold paper and boards into precise shapes for packaging and labels.

Now, dies are used to cut out custom shapes, while creasing rules, which are basically blunt edges, create fold lines without tearing the material.

And both of these actions often occur in one pass on a die cutting press.

Now here is an example of an industrial die with creasing rules included on it.

And you can see there a die-cut cardboard net, some of which the actual lines have been cut, and some of which have been creased using the creasing rules.

Industrial corrugation is performed on large machines called corrugators.

And softened paper passes between two corrugating rollers, which are large metal cylinders with gear-like teeth.

One roller is typically fixed, while the other rotates against it.

And the rollers have precisely machined grooves that press the paper into a fluted pattern under heat and also pressure.

So here is the fluted layer in the corrugated cardboard, which you will have seen before in corrugated cardboard of packaging, for example, or you may have used some in school.

You can also see it in this example here of a fluted outer layer on a coffee takeaway cup as well.

Okay, quick check for understanding on corrugation then.

During the corrugation deforming process, paper is pressed into a "something" pattern under heat and pressure.

Pause the video here, just take a moment to think about what that missing word could be.

Okay, and the correct answer was that "fluted," okay? So, during the corrugation deforming process, paper is pressed into a fluted pattern under heat and pressure, and that fluted pattern creates that wave of the material in the middle there.

Now, automated folding and glueing is a high-speed manufacturing process used to assemble flat-cut paper and boards into a finished product.

The process uses a folding and glueing machine, which automatically folds pre-creased areas and also applies adhesive in really precise locations.

The glued parts are then pressed and held briefly to ensure strong bonding.

So here are some examples of folded and glued cardboard boxes.

And again, you may have seen these in some packaging or any deliveries that you've had of products to your house at home.

Now, in industrial settings, dies and formers are often made from metal such as aluminium and steel.

Now, the reason these are chosen are because they are strong.

That makes them ideal for repeated use, which is going to happen a lot in industrial manufacturing.

They are also highly accurate as well, and the dies are usually CNC machined.

And of course, they're durable, and that's incredibly important.

They can withstand heat, pressure, and also moisture.

Okay, quick check on that then.

Why are dies, jigs, and formers used in industry made from metal? Is it: A, they provide strength and precision for repeat shaping; B, they are easier to shape; C, they are flexible; or D, they are recyclable? Just pause the video here to have a quick think about your answer.

The correct answer then is: they provide strength and precision for repeat shaping.

So that is why metal is used for the dies, jigs, and formers when we're using them in industry.

Okay, it's going to be over to you now to have a go at a few more tasks.

The first thing I'd like you to do then is to explain why industrial deforming processes are more suitable than small-scale methods for higher-volume production.

I'd then like you to produce a diagram of the steps involved in industrial embossing, and I'd like you to include labels on that as well.

The third task I'd like you to do is just answer this question: what is the role of a die in an industrial deforming process? And lastly, another question for you: what is the role of a former in an industrial deforming process? Remember, when you're answering the questions, try to use full sentences.

Okay, pause the video here to have a go at these four tasks, and good luck.

Okay, let's take each one of these questions in turn, then, and look at some example answers for you to compare yours to.

So the first thing I asked you to do is to explain why industrial deforming processes are more suitable than small-scale methods for higher-volume production.

So the example answer says this: The use of machines and automation help to produce complex shapes quickly and consistently.

This ensures every product is identical, which is essential for higher-volume production.

Just compare your answer to that and see if you've got all the key points in there.

Okay, the second task I asked you to do then was to produce a diagram of the steps involved in industrial embossing, and I asked you to also include labels in this.

So in this example, it's been broken down into three stages.

The first one showing the negative former and the positive former, and the sheet material placed in between it.

The second example shows then the heat and pressure being applied, and the heat is shown through those arrows being shown from above.

And the pressure, of course, means that the two formers are now pushed together.

And the third part of the diagram then shows the two formers being separated and the material being removed.

When you are asked to do something like a diagram for this, you should always include the material being removed and show that the material has changed shape to show your understanding of what shape the material would go into from the moulds or the formers that you have drawn.

The third task I asked you to do then was to consider the question: what is the role of a die in an industrial deforming process? So an example answer for you here then: In industrial deforming processes for paper and boards, a die is used to cut or crease the material into specific forms or patterns.

And the last question was: what is the role of a former in an industrial deforming process? And the example answer says: A former supports the material as it takes shape.

There are usually two parts: positive and negative.

Again, just like before, just compare your answer to these and just check that you've got the key and most important points included in your answer.

Okay, so let's summarise today's lesson then.

Today we've been looking at deforming manufacturing processes for paper and boards.

Now, deforming involves using force to change the shape of a material.

And small-scale production methods can be used to deform materials.

Deforming materials on a larger scale, however, require different techniques.

And we've looked at those different kind of smaller-scale manufacturing and also the larger-scale manufacturing in the lesson today.

Thank you so much for all of your hard work for today's lesson.

Thank you for joining me, and I will see you soon.