DT8: Papers and Boards
Paper types (layout, cartridge, tracing, tissue), board types (corrugated, foam-core, solid white board, mounting board); properties, uses, manufacturing processes.
Papers and Boards
Paper types (layout, cartridge, tracing, tissue), board types (corrugated, foam-core, solid white board, mounting board); properties, uses, manufacturing processes.
Key Fact: Cartridge paper: 120-300 gsm, textured surface, good for sketching and marker work.
Key Fact: Corrugated board: two liner layers with fluted medium - excellent crush resistance, lightweight, used for packaging.
Key Fact: Foam-core board: polystyrene foam sandwiched between card layers - very lightweight, rigid, easy to cut; used for architectural models.
Key Fact: Solid white board: high-quality bleached board, 200+ gsm - smooth surface for printing and packaging.
Key Fact: Tracing paper: translucent, 40-90 gsm - used for overlay work, developing ideas, transferring designs.
📋 Key Vocabulary and Concepts
For Papers and Boards, you must know:
- GSM (grams per square metre)
- Cartridge paper
- Corrugated board
- Fluting
- Foam-core board
- Solid white board
- Folding box board (FBB)
- Tracing paper
- Layout paper
- Tissue paper
- Bleed-proof paper
- Mounting board
- Creasing
- Scoring
- Die-cutting
❓ Practice Questions
Q1: Explain why corrugated board is used for packaging rather than solid cardboard of the same weight.
Q2: A designer needs to create a 3D architectural model. Justify the choice of foam-core board over corrugated board.
Q3: Compare the suitability of cartridge paper and layout paper for producing a final design presentation.
✅ Answers
- Corrugated board's fluted structure creates air gaps between liners - this gives excellent compressive strength and cushioning while remaining lightweight. Solid cardboard of the same weight would be thinner and offer no cushioning.
- Foam-core: very smooth surface, extremely rigid for its weight, cuts cleanly with a craft knife, accepts pins. Corrugated board: visible fluting on edges, less refined. For architectural models, foam-core's clean finish and rigidity make it superior.
- Cartridge paper (120-300 gsm): thick enough to stand alone, textured surface holds ink well, professional. Layout paper (50-60 gsm): thin, semi-transparent - for rough layout work, not final output.
🎯 Exam Tips
- Always specify the GSM when discussing paper weight
- Link board structure to function - explain WHY corrugated's fluting provides strength
- Know the difference between paper (below 200 gsm) and board (above 200 gsm)
📝 Exam Technique
D&T Exam Tips:
When justifying paper/board choices, use SFP: Surface (smooth/textured), Function (rigidity, foldability, protection), Process (printing method, die-cutting compatibility). Always match the material to the specific product requirements.
When justifying paper/board choices, use SFP: Surface (smooth/textured), Function (rigidity, foldability, protection), Process (printing method, die-cutting compatibility). Always match the material to the specific product requirements.
⚠️ Common Errors
Watch Out!
Students often make mistakes here. Wrong: Thicker paper is always better because it is stronger and more professional. Correct: Thickness must suit the function: tissue paper is perfect for delicate gift wrap; tracing paper needs translucency; cartridge paper needs weight and texture. Over-specifying GSM wastes material and increases cost.
✍️ Model Answer
Full-Mark Response
A company is designing packaging for a luxury perfume bottle. Justify the choice of board materials for both the inner protective insert and the outer presentation box.
A grade 9 response will: identify inner insert requirements (cushioning, precise cut-out for bottle, lightweight, no scratching); select foam-core or moulded pulp board. Outer box requirements (rigidity, premium surface, clean fold lines); select solid white board or rigid box board (500+ gsm) with wrap-around print.
📊 AO Deep Dive
Assessment Objective Analysis
AQA D&T 8552: Written exam 50% + NEA 50%. AOs: AO1 Recall (20%), AO2 Apply (30%), AO3 Analyse & evaluate (50%). For grade 9, show perceptive understanding of how paper/board properties serve specific packaging functions.
📝 Exam Questions by Topic
🎬 Video Resources
Detailed Notes
Paper Grades and Manufacturing Processes
Paper is manufactured from cellulose fibres derived primarily from wood pulp, though cotton and recycled fibres are increasingly important in UK manufacturing. The Kraft process produces strong, durable papers used in packaging, while the mechanical pulping process retains lignin, producing less durable but cheaper papers such as newsprint. In the UK, James Cropper in Cumbria specialises in high-quality bespoke papers, supplying luxury packaging brands including those used by British heritage companies. Understanding the manufacturing process is essential for GCSE students because it directly determines the working properties and sustainability credentials of each paper type.
GSM (grams per square metre) is the standard measure of paper weight and a critical specification in any GCSE D&T response. Papers below 200 gsm are classified as paper, whilst those above 200 gsm are classified as board. Layout paper (50-60 gsm) is thin and semi-transparent, ideal for initial sketches and overlay work. Cartridge paper (120-300 gsm) has a slightly textured surface that holds pencil, ink and marker effectively, making it the most versatile paper for design work. Bleed-proof paper has a coated surface that prevents marker ink from soaking through, essential for high-quality presentation graphics.
Example
A GCSE student designing packaging for a British artisan chocolate brand selects 350 gsm solid white board for the outer box because it provides the required rigidity for a luxury product, accepts high-quality lithographic printing for the brand identity, and can be creased and folded cleanly using a box-press. They pair it with 120 gsm cartridge paper for an inner sleeve that holds the chocolate tray, choosing a lighter weight to reduce material cost and waste whilst still providing adequate protection.
Board Types and Their Applications
Corrugated board consists of a fluted medium sandwiched between two liner boards, creating a structure with excellent compressive strength and cushioning properties. The fluting acts as a series of tiny arches, distributing force across the surface. Single-wall corrugated board (one fluted layer between two liners) is the most common type used in UK packaging, whilst double-wall provides additional protection for heavier items. DS Smith, a London-based multinational, is one of Europe's largest corrugated packaging manufacturers, supplying UK industries from food retail to electronics.
Foam-core board comprises a polystyrene foam centre between two smooth card layers, making it extremely lightweight yet rigid. It cuts cleanly with a craft knife, accepts pins and adhesives, and is the standard material for architectural models and presentation mounting in UK design education. Mounting board is a dense, rigid board used for framing and display work. Solid white board (200+ gsm) has a smooth, clay-coated surface ideal for high-quality printing. Folding box board (FBB) is specifically engineered for folding cartons, with multiple layers that provide stiffness whilst allowing clean creasing.
Example
A UK electronics company shipping tablets uses double-wall corrugated board for the outer shipping carton because the two fluted layers provide superior crush resistance during courier transit. Inside, the tablet sits in a custom-moulded insert made from solid white board, which provides a premium unboxing experience with a smooth printed surface showing the brand logo and compliance information required under UK regulations.
Sustainability and Environmental Considerations
Papers and boards are inherently renewable materials when sourced from sustainably managed forests. The FSC (Forest Stewardship Council) and PEFC certifications guarantee that raw materials come from responsibly managed sources. UK exam boards expect students to address sustainability in their NEA portfolios, and choosing FSC-certified board is a straightforward way to demonstrate environmental awareness. The UK recycles approximately 70% of paper and board packaging, one of the highest rates in Europe, driven by the Packaging Waste Regulations.
Recycled content paper uses post-consumer waste, reducing the demand for virgin pulp and diverting waste from landfill. However, each recycling cycle shortens the cellulose fibres, reducing strength. Most UK-manufactured recycled board blends recycled and virgin fibres to maintain performance. Students should understand that selecting a paper or board involves balancing sustainability, cost, and functional performance. For example, a food-contact packaging application may require virgin board to meet UK Food Standards Agency hygiene requirements, even though recycled board would be more environmentally favourable.
Example
A student designing eco-friendly seed packaging selects 200 gsm recycled FSC-certified cartridge board for the packet, printing with vegetable-based inks to minimise environmental impact. They include a specification note in their NEA portfolio explaining that whilst recycled fibres slightly reduce tear strength, the packet only needs to protect seeds during retail display, so the sustainability benefit outweighs the minor strength reduction.
Comparison
Paper and Board Properties Comparison
| Material | GSM Range | Key Property | Typical Use | Cost |
|---|---|---|---|---|
| Layout paper | 50-60 | Semi-transparent, smooth | Initial sketches, overlays | Low |
| Cartridge paper | 120-300 | Textured, versatile | Design work, marker render | Low-Medium |
| Corrugated board | 200-400 | Fluted core, crush-resistant | Shipping packaging | Low |
| Foam-core board | N/A | Lightweight, rigid, clean-cut | Architectural models | Medium |
| Solid white board | 200+ | Smooth, clay-coated | Premium packaging, printing | Medium-High |
| Folding box board | 200-450 | Multi-ply, creasable | Folding cartons | Medium |
Extended Practice
Q1: A packaging company needs to protect a fragile ceramic vase during UK courier delivery. Compare the suitability of double-wall corrugated board and foam-core board for the outer packaging, justifying your choice with reference to each material's working properties and the specific functional requirements of the application.
Q2: A GCSE student is creating a presentation board for their NEA portfolio. Explain which paper type they should select for the final rendered design and which for preliminary sketches, justifying each choice with reference to GSM, surface quality and intended function.
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