An article outlining the manufacture of cut flush binders
Since the "Cut Flush" binder is by definition created from a single piece of material, the finished binder is the simplest of all styles.
There are two basic manufacturing techniques for cut flush binders. One utilizes a die cutting machine and the other is accomplished by the use of a guillotine cutter, round cornering and hinging equipment.
The cover material is purchased either in roll or sheet form. If it is in roll form then it must be sheeted to the desired size to accomplish the greatest economy. Without a die cutter the sheets would be placed in the guillotine cutter and cut to the finished binder size. It is very important that finish size is cut perfectly square.
The next step is to decorate the sheet stock, ensuring that the spine copy is placed in the center of what will become the spine. When silk screening, it is important that the sheet lays perfectly flat for optimal screening. Once the scoring operation has been performed the sheet has a tendency to buckle up at the spine area, providing an uneven screening or decorating area.
The final operation involves scoring the hinges. The scoring bars selected must be the proper scoring bars for the desired capacity binder. Extra caution is taken to ensure proper scoring, with each hinge being the exact same measurement from the center of the sheet.