Paperwork and Cardboard Construction Techniques
This domain covers making artefacts from paper and board - folders, boxes, mounts, display boards - by scoring, folding, gluing and assembling accurately, then checking squareness.
Score before you fold
- A score compresses the board along the fold line so it folds without cracking the printed surface. Use a bone folder, scoring tool or rotary creaser.
- Fold towards the score and rub the fold flat with a bone folder.
- Fold along the grain wherever the job allows.
Plan the net
- Draw the net (development) full size, marking floor, walls, glue tabs and lid clearance.
- Add board thickness allowance at every fold; a lid must be 1–2 mm larger than the base it covers.
- Make a jig or template for repeat work so all pieces match.
Assembly
- Apply adhesive thinly and evenly, then press under weight until set.
- Mitre or notch corners so they lie flat without bulk.
- Check square by measuring both diagonals; they must be equal.
Worked example
A lidded box in 1 mm board with base outside 100 × 70 × 30 mm. Base net: floor 100 × 70 mm, four walls 30 mm high, glue tabs 10 mm wide. Add 1 mm at each corner fold for board thickness, giving a flat net of about 122 × 92 mm. Lid: inner size = base outer + 2 mm clearance, so 102 × 72 mm, with 15 mm walls. Without that clearance the covered lid jams.
Traps
- Folding unscored board, which cracks the liner and shows white lines.
- Glue tabs that are too narrow, so the corner pulls apart.
- Using too much paste, which warps the board as it dries.