MAKING SURE AT THE MONOTYPE WORKS

[Music] [Music] [Music] words in print. printed words. Words that have the magical power to entertain, to instruct, or to influence because they are seen in print. Silent voices speaking at every turn, telling of the things that should be known as often as the effort is made to read them. But today with all the vocal competition relayed from loudspeakers, it has become essential to make sure that the voice of the printed page, the type face in which it is set, shall attract and delight the reading eye. More than 500 designs of type have been cut for monotype machines to meet the needs of publishers and printers all over the world. [Music] There is a stage at which both artist and manufacturer are at last convinced that a really good printw worthy design has been evolved. A glimpse of the marvelous technical processes involved in the production of a good tight face will reveal what skills and precision techniques are called upon in the actual making of monotype mattresses. [Music] The original design is placed in a projector and the image enlarged many times is thrown onto a glass screen to which drawing paper has been attached. The outline of the character is drawn by hand on this paper. [Music] Sometimes it is desired to reproduce an ancient type design. The procedure is much the same, using a font of actual type and projecting it by reflection. [Music] The outline is drawn as before, although the magnified reflected image presents a different appearance on the screen. [Music] It may be necessary to reproduce the type from some old book printed in the days before modern methods of type production, perhaps from a hand engraved type face. The page from the book is placed in the projector and focused letter by letter onto the screen for copying. [Music] [Music] [Applause] Great care must be taken in all these drawings for this is only the beginning of a long series of operations. The type drawing office, as its name implies, is the draftsman's office for type designing. And it is here that the outline tracings from the projection room are perfected to ensure the correct reproduction of the original design. [Music] The quick firm strokes and the unhesitating selection of the correct curves are ample evidence of long practice and the skill of the personnel working here. Even so, this drawing will be carefully inspected and checked before passing on. And here is the wax pattern cutting department. After this drawing has been lined up and fixed to the table of the panagramraph, a wax sheet mounted on a glass plate is placed in the appropriate holder at the reducing end of the panagramraph. It is interesting to mention here that this carefully blended wax has been created to give the cleanest cut and make the strongest pattern. [Music] With the appropriate curves and rules, the outline of the drawing is traced with a stylus of the instrument. The selection of the correct curves and portions of curves is just one of those things which practice and skill make possible. As the reduced design is cut through the wax surface line by line and curve by curve, it can be seen how important is the correct blend of wax. Too soft and it would not cut clean. Too hard and it would chip at the edges. Even the temperature is of importance. And the plate on which the wax is fixed is heated under thermostatic control. Like all processes at the monotype works, it must be right. [Music] When the cutting of the outline is complete, the surplus wax between the lines must be removed. An operation requiring a steady hand and no mean skill. [Music] The wax pattern on its glass support now goes to the plating department. A silver nitrate solution is poured over it and is allowed to stand long enough for a fine film of silver to be deposited on the wax surface. As wax and glass will not conduct electricity, it would be impossible to induce a deposit of copper on the wax pattern without this process. The silver coating will conduct the current carrying the copper in solution and enable it to grow a shell conforming in every respect to the original wax pattern. [Music] [Music] After a thorough washing, the pattern is carefully fitted onto a special folder which enables the pattern to be suspended. in the electrolytic plating tank. [Music] After an allnight suspension in the tank, the required thickness of copper is obtained. And after the removal of the wax foundation, it is seen to be an exact replica in reverse. To provide a solid pattern for subsequent operations, the hollow back must be filled with a lead alloy. Even this seemingly simple operation requires preparation if the lead is to adhere solidly to the copper. The shell is fluxed and thin sheets of tin foil are placed in position and the pattern is placed on a hot plate. [Music] In a very short time, the tin melts and coats the copper surface, ready to receive the molten alloy. [Music] With its rough edges and uneven back, it requires yet more treatment before it can fulfill its proper function. A circular saw and a shore hand removes the rough edges and the trimmed pattern is passed on to the next operation. This milling machine now removes from the back all surface lead and brings the thickness of the pattern down to the correct working dimensions. [Music] After a few more operations, the pattern is passed back to the type drawing office for its final check under the microscope. It is marked with an appropriate reference number for future identification. [Music] And now the pattern comes to the punch cutting room where rows of panagramraphs are busy cutting punches from similar copper patterns. [Music] [Music] placed in position on the machine. The pattern is the master around which the stylus is moved to guide the punch blank in such a way as to cause the rotating cutter to cut a smaller replica on this blank. The tiny cutter meticulously adjusted in its holder is placed in position. [Music] The soft steel blank from which the punch is made is placed in a special holder and fixed in position above the cutter. [Music] On the tip of the stylus, a series of graduated followers allow the stylus to be brought progressively closer to the edges of the pattern. In like manner, the cutter is cutting nearer the edge of the letter. The followers are housed in a rotating holder and the operator changes from one to the next with the greatest dexterity. [Music] briefly as she finishes with each follower. She alters the depth of cut and starts all over again with the next size follower and so on until the whole series has been used. She removes the finished punch and examines it through a microscope to satisfy herself that it is correct as far as she is able to make it so. [Music] This is an enlarged view of a 12point perpetual cycling arm which he has been cutting. [Music] There are over 500 type faces and sizes range from 4 and a/4 to 72 points. For the larger sizes, a different machine is used but the procedure is the same. This machine is cutting a 72 point perpetual titling R. Obviously, on a punch of this size, much more metal has to be removed, but the same method of graduated pol is used. Cabinets at the side of these machines contain all the necessary sizes of polers for every point size. [Music] As the punches have been cut in soft steel, if steel can ever be called soft, they require hardening. After inspection, they go to the hardening department. [Music] Precisely timed heating and subsequent quenching in oil produces the hardness required for the job they have to do. [Music] This standard of hardness has to be maintained and each patch is machine tested to ensure uniformity of hardness to the monotype corporation standards. [Music] Make certain of the correct alignment of the ultimate type. The finished punch must now be justified. With the aid of a microscope, a honing stone, and a table of dimensions, the operator puts the finishing touches to this 72point punch. [Music] Every size receives the same treatment. The table of dimensions which originated in the type drawing office must now be used in the final check. [Music] At last, the punch is ready for use. A complete font sparkles like a collection of jewels. The special ornamental punches made to customers requirements have each followed through all these processes. [Music] In this well-lit and practically dustless department, the completed punch becomes the tool for the production of the matrix. One operation, the preparation of blanks for display mattresses, is satisfactorily performed by a blind man. [Music] His guide dog remains his constant companion. [Music] Display mattresses are pressed on these power presses which have been adapted for this special purpose in the corporation's own tool department. [Music] The punch and matrix blank are placed in the press and automatically positioned. When the foot pedal is depressed, a pressure of about 100 tons per square inch is applied to force the punch into the blank and reproduce the character. [Music] The two are then so closely knit that it's impossible to separate them by hand. [Music] So they are passed to another fixture which enables separation to be done quite quickly and easily. [Music] The perfect impression can be seen as they come apart. [Music] On this matrix, many machining operations follow. It has to be sized, faced, and checked. This milling operation takes care of the depth of the character in the matrix. And the limits are so fine that the setting of the machine has to be constantly checked through the microscope after each cut. [Music] Every printer is aware of the importance of perfect type height throughout the form. Present day attention to pre-make ready to increase productive capacity is evidence of this. The accuracy of the depth of the character in a monotype matrix plays an essential part in the final height of the type. [Music] Very few know how it is achieved and of the care which has to be exercised at every stage to make sure that the matrix which will be the mother of many pieces of type shall be good and true in every respect. [Music] With this high precision instrument, an independent check is applied to the depth of the character. Once again, ensuring that it presents not only a polished picture of perfection, even when enlarged, to the size seen here, but that dimensionally it is perfection itself. In the same room but on the opposite side, the 2 and 4 mattresses are made [Music] from coils of square rod. The matrix blanks are cut off automatically to the correct length and faced on the end in which the character will be struck. The actual square dimension of this blank is 1/5 of an inch. It is impossible to show some of the machining operations which follow as they are in covered automatic machines. [Music] GS are used in every case to load and take up the blanks after every operation. Protective guards prevent some of the machines being opened whilst running. The first process on the blank is the machining of the corners and the stamping of the reference numbers which can be seen on the right of this enlarged view. The press for making these smaller mattresses is another example of two room adaptation for special purposes. The galley containing the blanks is inserted side by side with an empty galley which will receive the punched blanks. The punch is inserted by means of a special holder and the press is started and runs continuously until the first galley is emptied. In addition to the type character, this same operation also punches a coned hole in the base of the blank. [Music] Here is a blank and both ends of a punched blank can be seen. As with display mattresses, so these composition matrices have to be milled correct for depth of the character. This automatic milling machine positions the matrix correctly, clamps it and carries it between a pair of cutters, maintaining correct depth of the characters and a constant overall length. [Music] The result of this operation can be seen on the right. [Music] For the purpose of fixing in the matrix case, a hole is drilled through each matrix. So that this hole shall be accurate, it is drilled from both sides. The correct position and alignment of this hole is assured by this method and the same system is for automatic operation is adopted in all these machines. [Music] [Applause] [Music] This shows the hole through the right hand matrix. The cone which was punched into the base is a very important feature and must now be machined out to its correct dimensions. [Music] This hole serves to position the matrix exactly over the mold in the caster where it is engaged by a centering pin at the moment of casting. It can therefore be seen that its exact positioning is very critical. The operation is tempting to watch, although normally concealed behind the protective guard of the machine. [Music] Apart from the loading and unloading of the galleys, this machine is automatic and therefore does not require an operator to be in constant attendance. [Music] The samples show the coned hole before and after machining. [Music] The duty of these girls is to keep the machines fed. As the mattresses near completion, they proceed through this room to where the final touches are made. [Music] For instance, the milling of the face has burred the metal slightly in the character aperture, and the operator is cleaning up the edges with a dexterity acquired through long practice. [Music] The debird edges can be seen in the sample on the right. [Music] They are then passed for final inspection in another department where a reflected image of the type face greatly enlarged is projected onto a screen for a dimensional check. [Music] The final operation is the milling of the sides to accommodate the spacing bars in the matrix case. [Music] And here is the completed matrix and the punch with which it was made. The finished mattresses are passed into the matrix store with the certainty that they will now conform in every way to the requirements of the original design and that any replacement of a matrix years later will be identical. When an order is received for a font of mattresses with a matrix case, the necessary mattresses are taken from the storage trays and sorted into the required arrangement for the case. This arrangement is picked up on block with a special tool and placed in a jig whilst the spacing bars are inserted. [Music] The bars are drilled to accommodate the rods, which also help to hold the mattresses in alignment. When it is realized that the holes in 16 bars and 17 mattresses must line up exactly to accommodate these rods, it'll be appreciated what a high standard of precision has been attained. [Music] [Music] The matrix case is inverted over this assembly and turned over. The wooden block and hammer is being used to tap the whole assembly into place. Those 15 rows of 35 holes are dead in line and the retaining rods slide in smoothly. They always do. [Music] The complete set of mattresses is now held securely in the matrix case with no tangible play. Yet each matrix can be individually influenced by the pressure of the centering pin whilst casting. A spring retaining clip is fitted and the completed case is ready for use on the casting machine. In this finished case, there are 1,024 surfaces which must mate exactly, and they do every time. And now to the marvels of the mold room. Another piece of precise mechanism closely related to the matrix is the mold in which the body of the type is cast. The overall height of the type is governed by the exactitude of the finished mold in conjunction with the perfect depth of drive of the matrix. This perfection in type height is all important in the modern pre-make ready method designed to affect time savings, increased production and better quality of printing. [Music] If it takes skill and experience to grind and lap two flat surfaces, how much more must be required to deal with curved surfaces? [Music] Some of these molds have a curve which is reproduced on the type in reverse. And the actual mating on two semicircles such as these calls for the utmost skill. [Music] And so the components are ground and lapped until the craftsman is satisfied they are correct. [Music] But even so it is not sufficient that he should be satisfied. All parts have to pass a more rigid test in a light comparator which will reveal errors of 140,000 part of an inch. As always, 100% inspection is required to ensure 100% perfection. That is the standard in this and every other part of the factory. [Music] The assembly of the composition mold is nearing completion. All the parts have been accurately located and attached, ready for the cross block to be inserted. [Music] The larger type of mold used in a monotype super caster is capable of producing sizes up to and including 72 points. These are just two of several different types of molds used on monotype casters. Molds which have to produce type, special designs, ornamental borders, rules and furniture. [Music] We have seen the care and precision used in the making and assembly of this matrix case. And now the time has come when these two important parts, the matrix case and the mold, must be brought together. This handheld demonstration shows their relationship and the movement in both directions as the perforated paper roll signals the correct character into position for passing [Music] in the machine. The correct matrix is automatically centered over the orifice of the mold for each successive character or space which is required to be cut. As each movement of the matrix case brings the character into position, the pump is depressed, sending a column of metal into the mold against the matrix. This solidifies almost immediately, and the type carrier moves it out, ready to make way for the next. Each piece is pushed forward as it emerges and positioned into lines of the required length automatically. [Music] A combination of levers and tongs at the back of the machine controls the movement of the matrix cape. They in turn controlled by the perforations of the paper roll release air which causes small stops to rise thereby lengthening or shortening the strokes and thus positioning the character over the mold. A system of movable wedges, also controlled from the paper roll, assures that perfectly justified lines are produced automatically. [Music] Behind the modern printer's amazing versatility stands this most clever and adaptable of all composing systems, this 20th century monotype machine. Behind this famous machine stands the British firm at whose works in S it is made by British craftsmen, engineers and typographic experts. And behind the machines and the people who make them is a vast army of printers in Great Britain, Europe, all over the globe. In fact, wherever good printing comes, monotype machines will be making sure that it is achieved economically and efficiently. 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