Production Aids With Papers & Boards (AQA GCSE Design & Technology): Revision Note
Exam code: 8552
The use of production aids with papers and boards
Production aids help papers and boards to be accurately:
Measured
Marked
Cut
Scored
Folded
Printed
Assembled
They are commonly used to make package nets, cards, leaflets, folders, cartons and models
Due to papers and boards being supplied as flat sheets, accurate layout and careful use of reference points are important for reducing waste
Measuring and reference points for papers and boards
Measuring and reference points are used to locate starting positions for dimensions, cuts, score lines, folds, print areas and joining tabs accurately on a sheet
A datum edge is selected first
Measurements are taken from this same straight edge rather than from several different edges
This reduces cumulative (a build up of) errors
A steel rule, set square, ruler, cutting mat grid or CAD coordinate system can be used to establish accurate lines and angles
Registration marks are printed reference points used to align colours, cutting, scoring or folding operations
Centre lines, fold lines and glue tabs may be marked using different line types so the maker knows which operation to carry out
A tolerance may be needed because card thickness, printing and folding can create small dimensional variations
Examples include:
Using the corner of an A3 sheet as a datum
Registration marks on printed packaging
A centre line for a symmetrical card net
A cutting-mat grid to position a sheet
Worked Example
Explain why all dimensions for a card package net should be measured from one datum edge.
[2 marks]
Answer
Measuring from one datum edge prevents small errors from being added together. [1] The cuts, folds and tabs are more likely to line up, so the package can be assembled accurately.[1]
Templates and patterns for papers and boards
A template or pattern is a reusable full-size shape, tool or outline used to mark or cut the same paper or board shape more than once
A template can be made from stiff card, acrylic, thin plywood or metal so that its edge does not quickly wear away through use during the marking out process
The template is placed on the sheet and drawn around, or it may guide a craft knife, router, laser cutter or digital cutter
A packaging pattern may show cut lines, score lines, fold directions, glue tabs and printed areas
Templates improve repeatability in batch production and are useful before the cost of a metal cutting die is justified
Shapes should be nested closely together to reduce offcuts and make efficient use of the sheet
Examples include:
A greetings-card aperture template
A pattern for a cereal-box net
A stencil for repeated printed graphics
An envelope template
Worked Example
Explain how a template could improve the batch production of 100 identical card folders.
[2 marks]
Answer
The same template can be positioned on each sheet and used to mark the outline and fold locations. [1] This makes every folder more consistent, speeds up marking out and reduces errors and waste.[1]
Examiner Tips and Tricks
When you are asked to explain the purpose of a template, do not just write that it makes the work "more accurate". On its own this is too vague to gain full marks. Instead, name a specific benefit and explain it: for example, it saves time when marking out, it lets you draw round the same shape to produce multiple copies, or it improves repeatability because every outline is copied from the same reference.
Jigs for papers and boards
A jig holds or locates paper or board
It is used to guide a tool so that an operation is repeated in the same position
Types of jig
A folding jig can include stops or blocks that position a card blank before it is folded along the same line each time
A drilling or punching jig guides a punch or drill when holes are needed for bindings, fasteners or display packaging
An assembly jig can hold the sides of a box at the correct angle while adhesive sets
A screen-printing jig or registration frame locates sheets of material so that each colour or image is printed in the correct position
Uses of jigs
Jigs are particularly useful in batch production because the setup time is spread over many identical items
Examples include:
A corner jig for gluing a card box
A hole-punching guide for ring-bound folders
A folding jig for invitations
A registration jig for screen printing
Worked Example
Describe a suitable jig for making holes in the same position on 50 card presentation folders.
[2 marks]
Answer
A drilling or punching jig could have a base, two locating stops and guide holes. [1] Each folder is pushed against the stops, and the punch passes through the guide holes so every set of holes is in the same position. [1]
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