Die-Cutting
Die-cutting is achieved mechanically using sharp steel rules
formed into the desired shape and set into a wooden die. Mounted
to a letterpress, these rules are designed to cut, score or
perforate when pressed against paper and a flat counter. Most
printers and binderies can provide standard dies for pocket
folders and other common projects. There is also a variety of
standard perforating rules to choose from—ask your printer
or bindery for the available options.
Dies can be produced
in combination with scoring or perforating to accomplish a multitude
of tasks in one impression. Custom designs are always a possibility,
but require more time and expense since the dies must be created
from scratch.
Scoring and Perforation
It is best to fold and score parallel to the paper grain, but
when a format requires folding in both directions, the primary
fold should be made parallel to the grain and the secondary
fold against it.
To get a crisp, accurate
fold on a text and cover sheet, score the paper first. Some
finishers recommend scoring every text and cover paper, others
only heavier stock. Covers and duplex covers should always be
scored before folding. There are four major scoring techniques:
Letterpress
score — Letterpress scoring, with a light pressure
score, is generally recommended and preferred. Most common
letterpress scoring methods are rule and counter, and channel
creasing matrix. A hot score will improve folding on more
difficult jobs and reduce the possibility of cracking.
Wet score
— This type of scoring is specifically for an uncoated
sheet. A special water attachment on the folding machine applies
a thin, straight stream if water where the paper is to be
folded. With damp fibers, the paper can not help but to create
a perfectly clean fold.
Press score
— Press scores apply the score inline while the job is
on press. Metal rules are set into a blanket that is on a
cylinder on the press. The pressure of the blanket presses
the scoring rule into the sheet as it passes underneath.
Perf and Crease
Attachment — There are perf and crease attachments
for folding machinery that can apply the score or perforation
during the folding process.
