Accessible Test

Flip-Over Concept Books - Line Paths

(Continued)
Technical Research first attended a PDC meeting in January 2008. There are two books under development; each book has 10 layers of three side-by-side panels that can be flipped individually in order to match the appropriate print/tactual images. From the beginning of this project, there has been a great deal of discussion and research on finding alternative methods to screen-printing on to vinyl. This would allow for a greater amount of colors than is typically considered the cut-off point of being cost effective. Technical Research did extensive research into different methods of printing directly on to vinyl, specifically the special controlled shrink vinyl that APH uses in many of its products. Technical Research worked with the Model Shop, scanning supplied art of all individual images, converting them into image files. Images were then placed within a master template based on positioning information also provided by the Model Shop. The merged files were imported into a CorelDraw format and provided to the Project Leader. The Project Leader was then able to follow the template and add colors of her choosing. The final file was next prepped by Technical Research and provided to a vendor with a Large Format UV printing system for having prototypes made for field-testing. This method was selected for field-testing because it was better suited for limited production quantities, even thought the quality was less than that of offset printing. Technical Research created a drawing for a cutting die needed for the field-testing (and likely production as well) and sent a request for quotes on making the die. Technical Research worked with a co-op engineering student to have a print test run on the large format printer at APH. Preliminary testing had proven unsatisfactory with the quality of the print being somewhat blurry and striations in the solid colors. Another problem with the print method had to do with compression of the print image, this prevented precise registration of the printed sheet and the vacuum-form mold. The compression was thought to have been the result of printing sheets on a roll feed system. The file was given to a second local vendor that has multiple large format systems to have a sample run. A sample printed on a flat bed UV printer had a much better appearance and the registration matched precisely. This sample was vacuum-formed to verify the registration. The Project Leader gave approval for this process for field-testing materials but wanted to continue to explore better printing methods. Additional vinyl was obtained to send to this vendor to satisfy the quantities of sheets needed for field-testing. While materials were being field tested, Technical Research continued to explore printing methods. By process of elimination, it appeared both Large Format and Flat Bed UV printing would not be a viable production method, leaving only offset printing as the only method that could insure print accuracy and registration. Several vendors were brought in to discuss our requirements. Of these, only two were agreeable to run tests. After some preliminary test, one of these vendors reported that they would not be interested in pursuing this work. The second vendor worked extensively with their ink suppliers and reported that they believed that they found an ink that was compatible with our vinyl. About a hundred sheets of vinyl as sent to the vendor for at test run in October 2008. Upon receipt of the printed vinyl, they were vacuum-formed to ensure that the ink would perform the same as screen-printed inks, i.e. they would not blister, crack or easily be separated from the formed sheet. These tests were 100% successful. This process not only opens the door for both expanded use of color in this product, but also allows realistic photo images to be printed on vinyl. During field-testing, the production binding department sent notice that the wire twin looping was being discontinued and replaced with plastic coil binding. The coil binding spacing was not compatible with spacing used for twin looping. This necessitated finding a new binding method. The Project Leader and Model Shop proposed having the vendor that manufactures plastic “Tuffy Rings” to create a custom injection mold that would produce a short, two-loop ring for APH. These short rings would be riveted, three side by side along the binding edge, providing the spacing required between each set of panels. Technical Research continued to research other binding methods and found a stock plastic “editable ring” that had promise. Samples were obtained, and after some skillful redesign by the Model Shop, this was found to be an acceptable solution. The binding method change had already required changes to tooling, so the Model Shop decided to move the spacing of the individual panels together, creating a smaller vacuum-form pattern, thus smaller sheets of vinyl. Technical Research worked closely with the Model Shop to facilitate these changes. Art created by Technical Research was reworked, plotted on clear film, and given to the Model Shop to create the production vacuum-form mold. This same art was used to generate the final print tooling and drawings for production cutting dies. This product was behind its original schedule because of the time required to research and develop a new process that will be used. Because of this, the Project Leader held a PDC meeting in March 2009, to update the production schedule. Part numbers for new materials were setup and quotes for pricing and availability were requested. Specifications were completed and turned over to Production in May. Because of the amount of work already in queue, the production departments could not commit to begin any work on this product until the pilot run in September, with the remaining production to be completed in November. With the two-month separation between the pilot and production runs, it was agreed to increase the pilot to 200 kits produced. The five cutting dies required to manufacture this kit have arrived and been approved. The printed vinyl sheets used for the flipbooks were received in July. Various components, including a screen-printed, vacuum-formed “Worksheet” set began in early August. At this time, the product is still on schedule for completion in September. Technical Research will continue to monitor this product through its first production run.