Woods, Paper & Card Theory Year 10

How paper and card is manufactured

Paper is a web-like material made from very fine vegetable fibres. Cellulose (the
cell wall in plants) is extracted from the wood to create these fibres.

The raw material is known as WOOD PULP. Chemicals are added to the pulp to
produce the required texture and surface finish.

1. Tiny chips of wood are cooked in water & chemicals to create mushy wood
pulp
2. The pulp is poured over a fine mesh
3. As the water drains away the cellulose fibres link together when they touch
4. The fibres pass through a set if rollers to remove the remaining excess
water. This strengthens the web of fibres

Stock forms
Different sizes: A1, A2, A3, A4 etc
Colours: a range of colours can be made using different dyes.
Surface finish: this can be altered depending on the rollers used
Different weights: (GSM) 100g per metre – 100g/m2, above 200g is classed as
board

Board
Board is the general term used for a range of paper-based materials
E.g. cardboard, carton board, mounting board, corrugated board

Board is made using several layers of pulp papers, so it’s thicker, heavier and
more rigid. Thick board is created by sticking layers of board together. This is
known as laminating.

Paper-based board can be laminated with a range of other materials, such as:
□ Aluminium foil
□ Plaster of Paris
□ Rigid plastic foams

These cards are known as composite materials

Types of paper
Paper Weight Description Uses Advantages Cost
Translucent so ideas
Thin, translucent, Sketching and Relatively
Layout 50 gsm can be traced and
smooth surface developing ideas expensive
altered
Thin transparentSimilar to layout, but
60/90 Can be
Tracing paper, smooth mainly used by Allows tracing
gsm expensive
surface. draftsmen
General use, Cheap when brought in
Lightweight, good
Copier 80 gsm Photocopying, inkjet bulk. Available in range Fairly cheap
quality paper
printer. of colours
 Creamy white General purpose More
120-150
Cartridge paper, slight drawing, can be used Completely opaque expensive than
gsm
texture with paint copier

Types of Boards

Material Description Application Advantages Photo

Folding box A layer of Products that need to Cheaper than solid
board unbleached card be printed on both sides white board
between 2 of the same piece of
bleached, white card Can be printed on both
layers sides

Solid white Bleached card Expensive foods Looks high quality

board
Easter egg boxes Looks hygienic

Good printing surface

Duplex Layer of white card Cheap food package Lower Cost

board backed with
unbleached card to Cereal boxes High Strength
save money

Foil lined A layer of Drinks Cartons Is airtight and

board waterproof foil is waterproof
added to the card Some pre-packed foods
Strong visual impact

Corrugated Protective package for Strong and light (Good

Card electrical products strength to weight ratio)

Will absorb force of

minor impacts
Duplex Cast coating is an Expensive chocolates Extra smooth and shiny
board extra shiny surface surface finish
added to any type Books
of bleached card Looks expensive

Can be embossed

Woods Theory Year 10

3 Main groups of woods: Softwood, Hardwood & Manufactured Board

Hardwoods come from deciduous trees (tree that lose there leaves in winter)
These tend to be slow-growing. This often makes them harder.

Softwoods come from coniferous trees (tree that do not lose there leaves in
winter)
These tend to be faster-growing. This often makes them cheaper.

Natural characteristics
Grain pattern, Colour, texture, workability, structural strength

Hardwood Appearance Properties Uses

Very strong, tough, Furniture, veneers,
durable. doors, fences
Oak

Close grain works and Wood floor in your

finishes well, Hard and house Functional
strong but not durable furniture, tools, toys
Beech outdoors

Hard and Strong but not Expensive furniture,

easy to finish. Expensive veneers
Indoor work only
Mahogany

Very durable, Fire Fine furniture, chairs,

resistant, but quickly tables, shop fronts
blunts tools
Teak

Very light and very soft, Model making, life

but strong for its weight belts, rafts
Balsa
Softwood Appearance Properties Uses
Quite strong, Lots of General woodwork,
knots, durable when cupboards, shelves,
European preserved. cheap roofs.
redwood

Tough, easily worked, Indoor work only, low

straight grain. cheap cost furniture

Stika Spruce

Tough with fine grain, General woodwork,

prone to twisting fitted furniture

Parana pine

Strong, needs Furniture, plywood,

protection outdoors doors, windows.
(Xmas trees)
Douglas fir

Soft and weak. Very Weather boarding

durable against
weather, insects and
Red cedar rot

Stock forms for timber based materials

i.e. rough sawn, PSE, sheet sizes and mouldings;

□ Have a basic understanding of the source of timber and the primary

processes involved in conversion to workable materials.
Manufactured boards are timber sheets that are made from gluing wood layers
(veneers) or wood fibres together. The benefits of these boards are:

• Large sheet sizes available

• A range of thicknesses easily available
• Desired properties can be created
• A consistent quality can be gained

Board Appearance Properties Uses

Made from compressed wood Cheap floor
chips.Strength varies with density of boards, self
board. Bonded with resin. Often assembly
veneered to improve appearance. furniture
Chipboard Cheap

Higher density when chipboard, Furniture, model

therefore stronger. No grain, strong, making
though edges need treating before
MDF painting. Cheap

More info...

Layers of wood bonded together with

grains at right angles to each other, Flooring,
very strong. furniture
Plywood

Blocks of cheap wood sandwiched Furniture

between thin sheets of better quality
wood. Very strong.
Blockboard
 Made of sawdust, similar to MDF. Construction
Smooth on one side and rough on the material
other. Very cheap

Hardboard

Key terms are needed when referring to materials:

Properties of a material – the key features/benefits of a specific material

Stock forms – ways in which material is available (sheet/granules/t section)
Primary processes – key processes needed to create a workable material
Raw material – An unprocessed natural product used in manufacture
Texture – the feel of a surface or a fabric
Surface finish – The level of smoothness of a part's surface after it has been
manufactured
Lamination – gluing layers of a material together to create beneficial properties
Composite material – A combination of two or more materials

Making paper (industrial) http://www.youtube.com/watch?v=7SdJtYkAzTw

Making paper (by hand)

Making timber boards http://www.youtube.com/watch?

v=PIwCaFJ0UGU&feature=related

Making plywood boards http://www.youtube.com/watch?v=hH86eahxeq8

Sand casting process http://www.youtube.com/watch?v=rgL2Jn5mk1A

Injection moulding machine parts http://www.youtube.com/watch?v=l1jNrmpx-

Rw&feature=related

Injection moulding process

Blow moulding http://www.youtube.com/watch?v=vSabFFQUr9E&feature=related

How plastic bottles are made http://www.youtube.com/watch?v=T01i_vp2mJE