Commercial Processes For Papers & Boards (AQA GCSE Design & Technology): Revision Note
Exam code: 8552
Offset lithography
Offset lithography is a commercial printing process in which inked images are transferred from a printing plate to a rubber blanket and then onto paper or board
It is used for large scale printing tasks
How does lithographic printing work?
A plate is made for each colour of an image, with each image requiring four different colours, therefore four plates
There are four colours (known as CMYK) to the process which are:
Cyan
Magenta
Yellow
Black
Each plate attracts ink onto an image areas and water to a non-image areas
The image is transferred to a rubber-covered cylinder before being pressed onto the paper or board which passes over the surface
Large sheets are printed quickly and are later cut, folded or die cut
Typical uses
Magazines, books, leaflets, cartons and high-volume packaging
Quality and production
It has high set-up costs but produces fast, consistent and high-quality results in large quantities
Registration must be checked so the colour layers align
Worked Example
Why is offset lithography suitable for producing 50,000 colour leaflets?
[2 marks]
Answer
Once the plates and press are prepared, the process prints very quickly and consistently. [1] The high set-up cost is spread across the large quantity, reducing the unit cost. [1]
Die cutting
Die cutting uses a shaped steel cutting rule mounted in a die to cut, crease or perforate paper and board repeatedly
How does die cutting work?
A die is manufactured to match the required net or outline
Printed sheets are aligned using registration marks or guides
The die is pressed into the sheet to cut the outline and may also create crease or perforation lines
Waste material is removed and the finished parts are folded or assembled
Typical uses
Packaging nets, greetings cards, labels, folders and display products
Quality and production
It produces identical components quickly accurate registration is essential where the cut must line up with printed graphics
Worked Example
Explain why die cutting is more suitable than hand cutting for a batch of 2,000 cartons.
[2 marks]
Answer
The die cuts the same complex shape quickly and accurately each time, [1] giving consistent cartons and a lower labour cost per unit. [1]
Examiner Tips and Tricks
When you're asked why a commercial process like die cutting or offset lithography suits large-scale production, always explain the specific mechanism rather than writing 'cheap', 'fast' or 'efficient', words like these score zero without technical explanation of the process.
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