How to Join Card and other Lightweight Materials

This article summarises different ways to join card and other lightweight materials in graphic products, including temporary joints, permanent joints, pop-up features, and rotating mechanisms. It concludes with examination questions to help you revise this material.

Permanent joints cannot be undone without damaging the material (these joining methods are not intended be taken apart afterwards).

PERMANENT LIGHTWEIGHT JOINTS

Glue tabs

Properties

Uses

Tabs should be angled at edges so they tuck in easily

Joining card packaging nets

You must mention an appropriate glue for the material. See different adhesives here.

Double-sided tape

Properties

Uses

Sticky on both sides (peel-off layers)

Doesn’t ‘run’ like glue

Hard to remove once attached

Bit fiddly and time consuming to apply

Attaching packaging windows

Staples

Properties

Uses

Quick and easy

Must be somewhere that the arm of the stapler can reach

Rough joints in cardboard

Snap rivets

Properties

Uses

Two-piece fasteners that push together and lock into position (often made from nylon or polypropylene)

Can be used to create a rotating joint if just one is used

Range of colours

Joining heavier card materials

Glue dots

Properties

Uses

Small sticky dots on a peel off sheet

Tidy way of sticking two lightweight items together

Mounting photographs

Positioning features in models

Zip-ties

Properties

Uses

End is threaded through hole and pulled tight

Useful for holding products in position against a cardboard backing

Cannot be undone (needs to be cut)

Packaging where the product is visible

Stitching

Properties

Uses

Only suitable for hand-crafted one-off items

Time consuming

Hand-made card products

Note: When manufactured, different card elements and other materials can also be permanently laminated together using adhesive, heat sealing or wet bonding (pressed together while being made)

Temporary joints can be undone without damaging the material (are designed to be easily taken apart).

TEMPORARY LIGHTWEIGHT JOINING METHODS

Tabs & slots

Properties

Uses

Various tuck-in tabs and slots (see detailed tab-and-slot ideas here)

Make sure closing tabs cannot be easily pulled undone

Velcro

Properties

Uses

Self-adhesive dots/strips or strips

Has two components – fine hooks and ‘wool’ that mesh together (can be pulled apart and re-joined)

Used on the opening of a box, so it can open and close

Brass paper fasteners

Properties

Uses

Simple devices used to bind paper together (also called split pins) – hole punched, then pin inserted and two legs split / bent

Unlike staples they can be easily removed

Creating rotating wheels and spinners in crafts and educational projects

Magnets

Properties

Uses

Magnets with an opposing thin mild steel plate can be glued between layers of card (self-adhesive magnetic sheets or strips can also be used)

Can be a choking hazard for young children (magnets are very dangerous if swallowed)

Temporary box closure mechanisms

Rubber bands

Properties

Uses

Easy to remove and put on

Stretchable

Can fall off / get lost

Securing items together

Keeping packages closed

Ribbons

Properties

Uses

Adds decorative element

Can come loose

Tying packages closed

Used as handles

String with eyelets

Properties

Uses

Eyelets (often made from brass or aluminium) strengthen/reinforce a hole, so that it doesn’t rip when string is pulled through it

Tying on labels

Photo corner stickers

Properties

Uses

Self-adhesive ‘corners’ that can be used for attaching photos or other items to a display (corner of card slots into triangular lip)

Photo albums

Clips

Properties

Uses

Various types of bulldog clips

Temporarily clipping lightweight materials together

These are not commonly used in graphic products, but may be useful when something needs to be moved or re-clipped by the user

Nylon bolts

Properties

Uses

Small and lightweight

Can tear through card if too much force is applied (used with a washer to help spread force over larger area)

Rotating mechanisms

ROTATING OR MOVING PARTS

Opening ‘mouth’

Properties

Uses

Double layer of card – inner layer cut and then folded to create mouth

Greeting cards

Slide-across tabs

Properties

Uses

Double layer of card, with a sliding strip of car between them which is manually slid across

Can push other moveable parts (such as the dog’s leg which extends or the ears which rise up)

Can reveal messages or other hidden images

Cards / poster displays

Pop-up portions

Properties

Uses

Raised up protruding portions (the can be the same material folded outwards, or new pieces glued on)

Additional images / parts can be attached to the pieces protruding out

Will lie flat and then pop open as card is opened

Birthday cards

Rotating disc

Properties

Uses

Rotating mechanism with paper fastener / split-pin, nylon bolt, or push rivet

Other methods include a thumb tack embedded in stiff card

Sample examination questions (AS Design & Technology)

Examiner comment: Many very creative responses were seen to this question. Most candidates were able to show a temporary method of attaching the corrugated card poster to the PVC frame. The most common answers included the use of slots, clips, push fittings, magnets, Velcro and plastic screw fasteners. The quality of sketches and notes was usually of a high standard and sufficient to communicate the joining method. A small number of candidates incorrectly showed a permanent method of attaching the corrugated card poster to the PVC frame.

Examiner comment: Most candidates were able to correctly explain how the foamboard discs could be secured and made able to rotate.

Amiria Gale

Amiria has a Bachelor of Architectural Studies, Bachelor of Architecture (First Class Honours) and a Graduate Diploma of Teaching. She is a CIE Accredited Art & Design and Design & Technology Coursework Assessor. Amiria now teaches Art, Design & Technology at ACG Parnell College.