Commercial and Industrial Processes: Die Cutting, Screen Printing, Sublimation Printing and CNC Routing

This lesson explores key commercial and industrial manufacturing processes as required by AQA GCSE Design and Technology (8552), Section 3.2.9. You need to understand how each process works, what materials it is suitable for, and when it would be used in industry.

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Die Cutting

What Is Die Cutting?

Die cutting is a manufacturing process that uses a shaped blade (called a die) to cut materials into specific shapes. It works like a giant cookie cutter — the die is pressed into the material with great force, cutting through it in one operation.

How It Works

1. A die is made by bending steel strip (called rule) into the required shape and mounting it onto a wooden or metal base.
2. The material (card, paper, fabric, foam, thin plastic) is placed under the die.
3. A press forces the die down through the material, cutting the shape in one action.
4. Creasing rules can be built into the same die to score fold lines at the same time.

Applications

Application	Material	Example Product
Packaging nets	Corrugated card, paperboard	Cereal boxes, pizza boxes
Labels and stickers	Self-adhesive vinyl, paper	Product labels, bumper stickers
Gaskets	Rubber, foam, felt	Engine gaskets, seals
Fabric shapes	Woven and non-woven fabrics	Shoe uppers, appliqué shapes

AQA Exam Tip: Die cutting is most often examined in the context of packaging. If asked how a packaging net is produced in industry, describe the die cutting process including the die, press and creasing rules.

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Screen Printing

What Is Screen Printing?

Screen printing (also called silk screen printing or serigraphy) is a printing process that uses a mesh screen to transfer ink onto a surface. It is one of the most versatile printing methods and can be used on paper, card, textiles, ceramics, metal and plastics.

How It Works (Step by Step)

1. A design is created and transferred to a transparent film (positive).
2. A mesh screen is coated with light-sensitive emulsion and allowed to dry in the dark.
3. The positive is placed on the screen and exposed to UV light. The emulsion hardens where light hits it.
4. The screen is washed out — the unexposed emulsion (under the design) dissolves, leaving open mesh in the shape of the design.
5. The screen is placed on the material, ink is applied to the top, and a squeegee is drawn across the screen, pushing ink through the open areas.
6. The material is removed and dried (or heat-cured for textiles).

Advantages and Disadvantages

Advantages	Disadvantages
Vibrant, opaque colours on any background	One screen per colour (multi-colour designs are expensive)
Can print on almost any flat surface	Set-up time is relatively long
Low cost per print in medium/large batches	Not economical for very short runs
Thick ink layer gives a high-quality finish	Fine detail is limited compared to digital printing

Real-World Examples

• Band t-shirts and promotional clothing
• Posters and art prints (e.g. Andy Warhol's screen-printed artworks)
• Printed circuit boards — solder resist layer is applied by screen printing

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Sublimation Printing

What Is Sublimation Printing?

Sublimation printing (also called dye-sublimation) is a digital printing process where heat converts solid dye into a gas that bonds permanently with polyester fibres or specially coated surfaces.

How It Works