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Last month, we indicated that over & over folds after the first broadside fold may be the most popular type of broadside fold. This fold can also prove to be the most difficult. As promised, we are going to go further into this topic for our July Helpful Hint.
You'll recall that a broadside fold occurs when the longer dimension of the sheet is fed widthwise into the folder; consequently, the product's running length is the shorter dimension. On a 28 x 40 sheet, for example, the first fold (the broadside fold) would bring the piece to 14 x 40.
Paper Stress: Causes & Remedies
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When a right-angle fold is performed after several over-and-over folds, paper stress will cause wrinkling inside the fold. |
Over & Over folds made at Right Angles to an initial broadside fold will create specific stress points in the product.
The pressure is created when the outer panels of the over & over fold are wrapped around the identically sized inside panels. When this occurs something must give. The fold forces the paper to buckle - with no room to move, the product will wrinkle, split, tear, or even double fold due to the fold sequence. (See diagram 1)
Technical Tip: Don't design more than 4 over & over folds at Right Angle to your initial broadside fold(s). Neither you nor your client will like the result.
Design Work Around: After the broadside fold, begin with accordion folds at Right Angle and then end with one or two wraps (over & over folds) to finish off the piece. This limits the amount of stress placed on the product, yet gives a similar look.
Product Note: For maps and instructions sheets, broadside folding typically isn't needed. In these cases, begin the fold sequence with accordion folds. This will dramatically reduce the stress on the stock for the subsequent Right Angle folds.
Push Out: Don't forget, when making folds at Right Angles to other folds, push out will occur. Essentially the paper will shingle, pushing out as much as 1/8". Ideally all binderies do their best to minimize the inevitable variations; however, it is necessary to advise your clients on what to expect. In general 1/16" will be common, with 1/8" being the exception.
The Rickard Advantage: We've logged thousands of hours working on broadside folds with over & over folds at Right Angle. While we can't eliminate the inherent design challenge we utilize our expertise to give you the best possible product.
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