Practical 3

 Practical 3 (Cardboard Joinery- Using different joinery to design a product)

Pre Experiment (Summary)

Corrugated Fibreboard is formed by a sheet of corrugated/ flute in the middle, and 2 layers of paper which is the outer and inner liners.

Outer liners are commonly made of Kraft Paper which is strong and easier to print. Inner liners are commonly made of Test paper which is a double layered paper and is cheap.

GSM- Grams per Square Meter. 125gsm Kraft Paper will be referred to as 125K.

Double or Tri walled material can be made by adding the needed amount of liner. Advantages of these are extra rigidity and strength.

Flutes come in many weights and sizes which affects the overall performance and cost of the final product. Composition can be tailor made for specific uses.

An example of Board Grade Naming is 125K/B/125T. We can understand as 125gsm Kraft outer liner, 125gsm Test inner lining and a B fluting. The order is as follows: Outer Lining/Grade/Inner Lining.

 

Flute	Thickness	Info
A Flute	5mm	-
B Flute	3mm	Exceptionally versatile
C Flute	4mm	Great compression strength.
E Flute	1.5mm	Excellent compression strength and crush resistance. Provided a high-quality surface for printing.
F Flute	2mm	-
BC Flute (Double Wall)	6mm	Good in all round performance. Common for producing shipping boxes
EB Flute (Double Wall)	4.5mm	Provides an excellent balance between transit protection, strength and print finish.

 

Flute	Grade	Product Weight
B or E	125 K/T	4-6 kg
B or E	150 K/T	8-12 kg
B or E	200 K/T	12-17 kg
B or E	200K/ 300T	17-25 kg
B or E	300 K/T	25-35 kg
BC or EB	125 K/T	10-15 kg
BC or EB	150 K/T	15-25 kg
BC or EB	200 K/T	25-35 kg
BC or EB	200 K/ 300T	35-40 kg
BC or EB	300 K/T	40-45 kg

Prior Knowledge

Terminology	Explanation of Terminology
Across Flute	Unit of measurement for corrugated in the opposite direction of the flute
Backing Liner	Compressible material which compensates for any irregularities on the sealed surface.
Blank	A flat piece of corrugated board that is cut and ready to form a box
Board Grade	Based on: 1) Weight and type of outer liner 2) Type of Flute 3) Weight and type of inner liner
Burst/Damage	Packaging containers that split open due to high pressure
Carton Board	Stiffer and thicker than boxboard. It has a medium to high compression and moisture resistance. Unlike cardboard, it is solid, and not fluted.
Chop Edge	Length of board/sheet
Clay Coat	A thin layer of kaolin coated onto corrugated board in order to improve its printing surface. Used on unbleached or natural Kraft paperboard.
Corrugated	Material that is shaped into a series of parallel ridges/grooves.
Crush	An edge crush test measures the cross direction crushing of corrugated board. It provides information on a board’s resistance to being crushed.
Deckle	The width of the board being run on a corrugator.
Double wall board	A combination of 2 layers of corrugated material to provide extra strength
Duplex	A type of paperboard made up of two layers, the exterior is often coated which makes it more water- resistant, often used for paper cups and plates in the pharmaceutical industry.
Edge crush test	Vertical crush resistant test for corrugated board
Enhances Fluting	A substitute to standard fluting that adds strength and performance to the material.
FEFCO	The European federation of corrugated board manufacturers are a non-profit organisation which represents the interests of the corrugated industry
FEFCO case codes	A set of standard design patters used in the industry
Fibre	Packaging materials made from moulded fibres/moulded pulp
Flute	Paper that provides the central layer in corrugated board (cardboard). Separated the liners and provides the strength and rigidity.
Fluting Profile	Shape o f the corrugations within the corrugated material.
Grammage	Weight of paper specified in g/m2
GSM	An acronym for the measurement of grams per square meter
Kraft	Brown paper of paperboard which has been produces from virgin pulp in the pulping process. Made out of natural unbleached wood fibres.
Light-weighting	Design of packages that reduce material use, hence reducing weight, cost and environmental burden
Liner	One of the paper materials which, make up one part of the components in corrugated board. There in an inner and outer liner; the outer liner is usually of higher quality, due to being used for print finish.
Mottled	A paper liner with an off white appearance
Single face	One piece of fluting glued to one liner only
Slit edge	The edge of the sheet that has flute running parallel with it. It is also known as the width of the material.
Test liner	Recycled liner board which can be manufactured as a sheet where the fibres are consistent throughout. The higher quality recycled boards should be on the outside.
Tri wall	Is triple fluted corrugated board which is used for its strength, flexibility and eco-friendliness.
Virgin material	A material which has not been processed in any form other than its original manufacture.
Weight	Density of a material

Different types of joinery learnt

Tab, Flange, Tabs and Slot, Zip Ties, Brass Fasteners, L-Brace, Slots, Gusset, Score and Bend

Safety 

In this practical, apart from designing with cardboard, we also had to cut and glue the cardboard together. We had to use things like penknives and hot glue guns

Penknife- When cutting with the penknife, do not cut from an awkward angle. Hold onto penknife firmly and use a ruler to guide the cut. Do not extend too much of the blade, only extend what we need to use. If one slice is not enough to cut through cleanly, do not remove the ruler, and slice again. 

PPE- When using sharp objects, make sure to wear gloves such as cut-resistant glove. Wear covered shoes and long pants.

Hot Glue Gun- Do not touch the hot tip as it will burn your fingers. Leave the got glue gun on a carboard when not using.

What we designed and built

We initially had 2 ideas, which is to built a house or a pinball machine. After careful discussion, we decided to build a pinball machine as it is more interactive. 

House:

Pinball Machine:

Pinball Machine

The walls are made of carboard with "Tab" and "Tab & Slot" joinery.

We had used "Score & Bend" to create the goal and a curved corner to allow the ball to enter the game area cleanly

To create obstacles on the board, we had used "Gusset, Flange and Slots".

To create the slingshot, we had used "Zip Ties and Brass Fasteners".

Work in Progress: 

Final Product: 

Functionality:

Presentation: 

The Little Assignment

Types of fold or joints used: Tabs, Slots, Tabs and Slots. 

Assembling Process:

Mechanism: 

To flap the wings, we need to push the bottom of the wing. This give the rubber band elastic potential energy. The elastic potential energy become kinetic energy and pulls the wing back to its original position.