Papers and Boards

In this section, we will cover important concepts related to papers and boards, which are commonly used materials in design and technology. These revision notes will focus on key areas like material selection, forces and stresses, ecological impact, and commercial processes.

Selecting Materials

When selecting papers and boards for a product, designers must consider various factors, such as:

• Strength: Does the material need to be strong enough to support weight or resist tearing? For example, cardboard is often used for packaging because it is strong and rigid.
• Weight: Some products require lightweight materials, while others need heavier options. For instance, newsprint is light, while cardboard is heavier.
• Aesthetic quality: The texture, colour, and finish of the material may be important, especially for products like greeting cards, packaging, or stationery.
• Environmental impact: How sustainable is the material? Recycled paper and board materials can reduce the ecological footprint.

Forces and Stresses

Papers and boards must be able to withstand different forces and stresses. These include:

• Tensile stress: The material is stretched, such as when pulling on paper or board.
• Compressive stress: The material is squashed, which is common in packaging, especially for corrugated cardboard.
• Shear stress: Forces act in opposite directions, like cutting or folding paper.
• Flexural stress: Bending forces that occur when the material is flexed, such as when bending thin cardboard or paper.

Designers need to understand the stress properties of papers and boards to ensure they are fit for purpose, whether the product needs to be lightweight or strong enough to carry a load.

Ecological and Social Footprint

The ecological and social footprint of papers and boards refers to their environmental impact and the social consequences of their production:

• Ecological footprint: This involves considering the materials' sustainability. Can they be recycled? Are they biodegradable? Recycled papers reduce the need for virgin materials, saving trees and reducing waste.
• Social footprint: The working conditions and social responsibility of paper mills and manufacturers are also important. Are workers treated fairly? Are ethical production processes followed?

For instance, FSC (Forest Stewardship Council) certification ensures that paper comes from sustainably managed forests, helping to reduce the ecological footprint.

Sources and Origins

Papers and boards are derived from plant-based fibres, primarily from wood pulp. However, they can also be made from other materials such as cotton, bamboo, or even recycled paper. The origins of the materials affect the overall sustainability of the product:

• Wood-based papers: Typically, these come from softwood trees (e.g., pine) or hardwood trees (e.g., oak).
• Recycled paper: Made from post-consumer waste paper or industrial offcuts.
• Alternative fibres: Some papers are made from agricultural by-products like sugarcane pulp (bagasse) or hemp.

The origin of the material affects both its environmental impact and cost.

Use of Material Properties in Commercial Products

The properties of papers and boards make them suitable for various commercial products:

• Newsprint: Lightweight, inexpensive, and good for printing newspapers.
• Cardboard: Rigid and strong, often used in packaging for protection during transportation.
• Corrugated board: Made from layers of cardboard, it provides strength and cushioning for packaging.
• Solid Bleached Sulphate (SBS): A high-quality, smooth surface paper often used for food packaging and premium product packaging.
• Kraft paper: Strong and durable, often used in packaging and wrapping.

In commercial products, selecting the appropriate material ensures functionality and cost-effectiveness.

Stock Forms, Types, and UK Sizes

Papers and boards are available in a variety of stock forms and sizes, which makes it easier to choose the right material for specific applications:

• Sheets: Available in various sizes, such as A4, A3, and A2 (standard international paper sizes).
• Rolls: Often used in larger-scale printing, such as for newspapers or posters.
• Board thickness: Available in a range of thicknesses measured in grams per square metre (gsm) for paper and in caliper (mm) for board. For example, thin paper might be 80 gsm, while a thick cardboard sheet could be 1200 gsm.

Standard UK sizes:

        A4: 210 x 297 mm

        A3: 297 x 420 mm

        A2: 420 x 594 mm

These sizes make it easier for designers to select materials that match their product dimensions or printing requirements.

Scales of Production

The choice of paper or board will also depend on the scale of production:

• One-off production: For prototypes or bespoke products, high-quality materials might be chosen, such as textured paper for luxury packaging.
• Batch production: Materials might be selected based on efficiency and cost, such as using standard A4 or A3 sheets for office printing or brochures.
• Mass production: Large quantities of standard materials, like newsprint or corrugated board, are used for high-volume production, like packaging for retail products.

Each production scale will influence the choice of material in terms of cost, availability, and performance.

Tools, Equipment, and Processes

When working with papers and boards, various tools and processes are used to manipulate the material:

• Cutting tools: Scissors, craft knives, and guillotines are commonly used to cut paper and board to size.
• Folding tools: Bone folders or scoring tools are used to create clean, precise folds in paper and card.
• Printing: Processes like screen printing or digital printing are used to apply ink to paper or board for marketing materials, packaging, and stationery.
• Binding: Stapling, gluing, and stitching are methods used to bind sheets of paper together in products like books or brochures.
• Embossing and debossing: These processes create raised or indented designs on paper or card, commonly used in packaging and luxury product design.

Commercial Processes

Papers and boards go through various commercial processes to become finished products:

• Pulping: Wood or other fibres are broken down into a pulp. This pulp is then turned into paper or board through a process involving water, heat, and chemicals.
• Pressing: The paper pulp is pressed to remove excess water and flatten the material.
• Drying: The material is dried to set its structure and ensure it is suitable for printing or other uses.
• Coating: Some papers and boards, such as glossy magazine pages or high-end packaging, are coated with materials like clay to improve smoothness and printability.
• Finishing: Involves processes like cutting to size, embossing, or laminating to provide the final product.

These processes determine the material's final properties, including texture, strength, and finish.

Summary

Understanding the properties, selection, and processes involved in using papers and boards is vital for successful design and product development. By considering factors like strength, sustainability, and manufacturing techniques, designers can make informed choices and create functional, aesthetically pleasing products. Remember to consider the material’s ecological footprint, its social impact, and the best commercial processes to optimise production and performance.