504 - Type in Context - Print & Foil Fail

My print slot went perfectly and I was able to individually bind each section of the book. I ordered the production this way so I could then trim each section to ensure perfect alignment and page dimensions, which would then be ready for foiling across the cover pages. 

I did not account well enough for the factor of the digitally printed inks getting heated back up again in the heat press upon foiling the covers - thus causing bits of foil to stick onto the non-adhered places on the cover. For my first attempt, I had only placed newsprint between each page of the publication thinking that this might absorb the heat and the pages would not stick together. But this was not the case and the inks completely sealed the book shut with the newsprint sticking out. With my second attempt I thought this problem could be solved by pressing it for a slightly less time and temperature (as Mike said I had it on too high on the last attempt, with regards to the printed inks inside) and then just to be sure, I also tried only having the cover pages under the press, so the rest of the publication could overhang out and not get heated up. However, this was hard to do precisely because of the way the heat press is laid out and I was careless, so unfortunately this attempt failed as some of the first few inner pages had stuck together and transferred again. 
From this experiment I learnt a valuable lesson - don't leave the final attempt to my last bit of left-over materials, as I could not afford any more running up to Christmas! I re-evaluated my options and started thinking about how I could get round this problem.

I had learnt that for actual industry production of the book and for if I manage to have another attempt before the final deadline, I need to foil before I bind any sections of the book, so I can put the cover pages in separately so no further ink melting will take place. In the 2nd section (as the first inner page is a full bleed image I will need to look into making the first inner page blank to avoid ink melting and sticking face down to the newsprint when put in separately - but without changing the whole pagination of the document (from a multiple of 4) so it is still accurate for a bound book. This could work in the sense of that first full bleed image will just have to be small sized one on the right hand page; and I'll just have to do the same on the back page spread aswell. Alternatively, I may look into replacing the whole foiling process (to avoid the heat press) and make use of metallic screen-printing instead, as I have seen examples of it being used and it gives a very similar and luxurious effect. 

Next time, to ensure perfect alignment whilst still being able to bind after the foiling, I will print and then only bodge the holes for stitching through, and not actually thread it through, ensuring consistency. I can then temporarily clip them together using those holes so it is held steady to trim accurately. This means I can then separate the cover pages from the rest of the publication to go and foil before permanently stitching the book together.

Can see how cover inks have melted and caused bits of foil to stick in not just the adhered areas.

Inner pages all stuck together





















For this reason I am glad to have planned in extra contingency time to try and correct errors that may take place, but even still I will run over the organised 'final' deadline (not final module submission so I can try again but I haven't met the brief deadline). This was down to no available print slots at such short notice.