Exam Style Questions: Paper and Board Forming Processes

Question 1

Define what is meant by the term creasing (2 marks)

Answer 1

The compression of the cellulose fibres (1) in a board or paper which makes the material easier fold (1).

Question 2

Other than creasing, name two operations that can be performed by a flatbed die (2 marks)

Answer 2

• Cutting

- Perforation

Question 3

The prototype of a pop-up card has been made by hand. Evaluate the benefits of using a laser cutter to create prototypes for products such as this (6 marks)

Answer 3

• Files can be edited rapidly using CAD
• Files are digital so quick and easy to share between colleagues
• Laser cutting produces a highly accurate finish
• Designs may be highly intricate
• Laser cutter can create cuts, scores and perforations
• Etching can be used to add surface patterns
• A range of materials can be experimented with using the same machine
• Once the laser cutter has been procured, the set-up time and set-up costs for each job is minimal; ideal for one-off or batch production
• Once the development process is complete the digital file can be adapted for use in other processes such as die-cutting

Question 4

Compare the advantages and disadvantages of rotary die cutting over flatbed die-cutting. You should refer to the following in your answer: (8 marks)

Environmental considerations
Advantages and disadvantages for the manufacturer 
Advantages and disadvantages for the client

Answer 4

• Rotary cutting is faster, so makes the best use of manufacturing time
• Rotary cutting is more efficient, so reduces unit costs and makes better use of energy
• Rotary cutting has higher tooling costs, so the print run would have to be high in order to justify the extra costs
• Rotary die cutters can be web-fed which is more efficient in terms of materials and time
• Changing the tooling on rotary die cutters is more time consuming which increases downtime between jobs
• Rotary die cutting has a higher level of accuracy so is preferable when making cuts with high tolerances e.g. kiss cuts
• Using a continuous roll of material can help reduce waste/offcuts, makes best use of material so is better for the environment / helps reduce costs
• Flatbed dies are best suited to shorter production runs as the set-up costs are lower
• Perforations and creases can be made with either flatbed or rotary dies
• The tooling for flatbed dies requires less storage space

Question 5

Name a suitable adhesive for joining foam core (1 mark)

Answer 5

• Polystyrene cement

- Hot-melt glue.

Question 6

Explain two precautions that should be taken when using solvent-based adhesives to ensure the safety of the user (4 marks)

Answer 6

Award 1 mark for relevant point and a further 1 mark for a suitable explanation.

• Well-ventilated area / spray booth / extraction / use of a mask (1) so fumes/VOCs
  are not inhaled (1).
• Use of gloves (1) to protect sensitive skin (1).
• Wear an apron (1) to protect clothes (1).
• Wear goggles (1) to protect eyes (1).
• Flammable (1) do not use near a source of ignition (1).

Question 7

Describe two advantages of using hot-melt glue to seal the pasta package (4 marks)

Answer 7

Award 1 mark for relevant point and a further 1 mark for a suitable explanation.

• Dries quickly (1) so easy to integrate into automated manufacture (1).
• Joints sealed with hot-melt glue can be torn open easily (1) so user-friendly (1).
• Non-toxic (1) suitable for use with foodstuffs (1).

Question 8

Explain how to apply and bond two surfaces using contact adhesive (4 marks)

Answer 8

Award 1 mark for each relevant point below, if listed in the correct order, up to a maximum of 4 marks.

• Ensure surfaces to be glued are free from dust (1).
• Apply a thin coat of adhesive (1) to both surfaces to be glued (1).
• Leave glue to go tacky/dry to the touch/for 5-20 minutes approx. (1).
• Push surfaces to be glued together, the bond should be instant (1).

Question 9

Discuss the advantages and disadvantages of using a jig to manufacture a batch
of 300 units of packaging (6 marks)

Answer 9

Advantages:

- Increase accuracy
- Increase efficiency
- Increases consistency
- Can increase safety
- Can make materials and tools easier to work with
- Requires a lower level of skill

Disadvantages:
- Jigs take time, money, and skills to manufacture
- Jigs require storage space
- Jigs may take time to install which creates downtime
- Jigs may be useless once the manufacture of a batch of products comes
to an end