Part 5

The manufacturing man sees that early copies of each new book, for copyright purposes, are furnished to the proper department that attends to that detail, and that early copies also are supplied to the publicity department, to place with editors for special or advance reviews.

The manufacturing man also provides the travelling representatives of his house with adequate dummies (i.e. partly completed copies) of all new books as soon as the important details of their make-up have been decided.

This brief outline covers all of the steps in the process of the evolution of a book. Reams, however, could be devoted to the innumerable details that interweave and overlap each other with which the manufacturing man has to contend, when, as is often the case in our larger publishing houses, he has from forty to fifty books, and sometimes more, in process of manufacture at one time. I know of no man to whom disappointment comes more often than to him,--from the delays due to causes wholly unavoidable, to the blunders of stupid workmen and the broken promises of others; but these are all forgotten when the completed book, that he has worried over in its course through the press, in many instances for months, reaches his hands completed, "a thing of beauty."

THE MAKING OF TYPE

By L. Boyd Benton.

Type are made of type metal, a mixture of tin, antimony, lead, and copper. As antimony expands in solidifying, advantage is taken of this quality, and the mixture is so proportioned that the expansion of the antimony will practically counteract the shrinkage of the other ingredients. The proportion of the mixture is varied according to the size and style of type and to the purposes for which it is used.

Type are cast separately in moulds, a "matrix" at the end of the mould forming the letter or other character.

Machinery is used very largely in modern type-making. The steps of its manufacture are in this order: drawing the design, producing of a metal pattern therefrom, placing the pattern either in the engraving machine to produce steel punches and type-metal originals, or in the matrix-engraving machine to produce matrices, adjusting the matrix to the mould, and finally, casting the type.

The design for a new style of type is made generally with pen and ink, the capital letters being drawn about an inch high and the others in predetermined proportions. When the design is for a plain text letter, similar to that with which this book is printed, it is essential to have the letters proportioned and shaped in such a manner as will cause the least strain on the eye in reading, and, at the same time, produce a pleasing effect when the page is viewed as a whole. When the printed page conveys information to the reader, without attracting attention to itself, it is ideal.

While this is true in regard to a design for a text letter, the design for a display type is often made to attract attention, not only to itself, but to what it proclaims, by its boldness and beauty and sometimes even by its ugliness.

After the design has been drawn, it is placed in a "delineating machine," where an enlarged outline pencil copy, or tracing, is made, so large that all errors are easily seen and corrected. New designs may, however, be drawn in outline by hand on the enlarged scale, thus rendering unnecessary both the pen-and-ink drawing and the tracing.

With the aid of the delineating machine, the operator, besides being able to produce an accurately enlarged outline pencil tracing of a design, is also enabled, by various adjustments, to change the form of the pencil tracing in such a manner that it becomes proportionately more condensed or extended, and even italicized or back-sloped. That is, from a single design, say Gothic, pencil tracings can be made condensed, extended, italicized, and back-sloped, as well as an enlarged facsimile.

The next operation consists in placing the enlarged outline pencil drawing in a machine which enables the operator to reproduce the outline drawing, reduced in size, on a metal plate, evenly covered with wax, with the line traced entirely through the wax. The plate is then covered with a thin layer of copper, electrically deposited, and is "backed up" with metal, and trimmed and finished, similar to an ordinary electrotype plate of a page of type. A copper-faced metal plate is thus produced, on which are the raised outlines of a letter. This is called the "pattern." From this pattern all regular type sizes may be cut. It determines the shape of the letter, but the size and variations from the pattern are determined later by the adjustments of the engraving machine in which it is used.

The pattern is now sent to the engraving room. Machines have superseded the old-fashioned way of cutting punches and originals by hand, and they have enormously increased the production of new type faces. Whereas in the old days it took about eighteen months to bring out a new Roman face, or style of letters, in seven different sizes, to-day it can be done in about five weeks. The reason is that formerly only one artist, known as a punch-cutter, could work on a single face, and he had to cut all the sizes, otherwise there were noticeable differences in style. By machine methods, where all sizes can be cut simultaneously, it is only a question of having the requisite number of engraving machines.

As to the quality of machine work, it is superior to hand work both in accuracy and uniformity. The artist formerly cut the punches, or originals, by hand under a magnifying glass, and the excellence of his work was really marvellous. However, when changing from one size to another, there were often perceptible variations in the shapes of the letters, or the sizes were not always evenly graded. By the machine method the workman uses the long end of a lever, as explained below, and has therefore a greater chance of doing accurate work. In addition to this, a rigid pattern forms the shape of the letter, and to it all sizes must conform.

Another gain the machine has over hand-cutting is its greater range. When the old-time artist made an unusually small size of type for Bible use, he did it with great strain on his eyes and nerves. At any moment his tool might slip and spoil the work. With the machine, on the other hand, and with no physical strain whatever, experimental punches have been cut so small as to be legible only with a microscope--too small, in fact, to print. At present there are two styles of engraving machines employed,--one cutting the letter in relief,--called a "punch" if cut in steel, and an "original" if cut in type metal,--and the other cutting a letter in intaglio,--called a "matrix." Both machines are constructed on the principle of the lever, the long arm following the pattern, while the short arm moves either the work against the cutting tool, or the cutting tool against the work. The adjustments are such that the operator is enabled to engrave the letter proportionately more extended or condensed, and lighter or heavier in face, than the pattern. All these variations are necessary for the production of a properly graded modern series containing the usual sizes. In fact, on account of the laws of optics, which cannot be gone into here, only one size of a series is cut in absolutely exact proportion to the patterns.

As it is impossible to describe these machines clearly without the aid of many diagrams and much technical language, only a brief description of their operation will be given.

When the letters are to be engraved in steel, blocks or "blanks" are cut from soft steel and finished to the proper size. A blank is then fastened in the "holder," the machine for cutting the letter in relief adjusted to the proper leverage, and the pattern clamped to the "bed." The long arm of the lever, containing the proper "tracer" or follower, is moved by the operator around the outside of the pattern on the copper-faced metal plate, causing the blank to be moved by the shorter arm around and against a rotating cutting tool. This operation is repeated several times with different sizes of tracers and different adjustments to enable the cutting tool to cut at different depths, until finally a steel letter in relief is produced, engraved the reverse of the pattern and very much smaller. After being hardened and polished, this is called a steel punch, and, when driven into a flat piece of copper, it produces what is known as a "strike" or unfinished matrix.

If in the same machine type metal is used for blanks, the resulting originals are placed in a "flask," or holder, and submerged in a bath, where they receive on the face of the letter a thick coating of nickel, electrically deposited. As soon as the deposit is of sufficient thickness, they are removed and the soft metal letters withdrawn, leaving a deep facsimile impression in the deposited metal, which also is an unfinished matrix.

The machine for engraving a matrix in intaglio is operated in much the same manner as that for engraving a punch in relief. The same patterns are used, but the operator traces on the inside of the raised outline instead of on the outside. Besides following the outline, the operator guides the tracers over all the surface of the pattern within the outlines; otherwise the letter would appear in the matrix in outline only. The matrices are cut in steel and in watchmakers' nickel, and the work is so accurately done that about half the labor of finishing is saved.

It will be noted from the foregoing that all three processes of engraving end in the production of an unfinished matrix.

The adjusting of the matrix to the mould is technically called "fitting," and requires great skill. If type are cast from unfitted matrices, be the letters ever so cleverly designed and perfectly cut, when assembled in the printed page they will present a very ragged appearance. Some letters will appear slanting backward, others forward, some be above the line, others below; some will perforate the paper, while others will not print at all; the distances between the letters will everywhere be unequal, and some will print on but one edge. Indeed, a single letter may have half of these faults, but when the matrices are properly fitted, the printed page presents a smooth and even appearance.

The mould for this purpose is made of hardened steel, and in it is formed the body of the type. The printing end is formed in the matrix. The mould is provided at one end with guides and devices for holding the matrix snugly against it while the type is being cast, and for withdrawing the matrix and opening the mould when the type is discharged. At the opposite end from the matrix is an opening through which the melted metal enters. The moulds are made adjustable so that each character is cast the proper width, the opening of course being wider for a "W" than for an "i." Only one mould is necessary for one size of type, and with it all the matrices for that size may be used. Commercially, however, it is often necessary to make several moulds of the same size in order to produce the requisite amount of type.

After the adjustments are made, the casting of the type follows. Type are now cast in a machine which is automatic, after it is once adjusted to cast a given letter. The melted type metal is forced by a pump into the mould and the matrix, and when solidified, the type is ejected from the mould and moved between knives which trim all four sides. The type are delivered side by side on a specially grooved piece of wood, three feet long, called a "stick," on which they are removed from the machine for inspection. Type are cast at the rate of from ten to two hundred per minute, according to the size, the speed being limited only by the time it takes the metal to solidify. To accelerate this, a stream of cold water is forced through passages surrounding the mould, and a jet of cold air is blown against the outside.

The automatic casting machine performs six different operations. Formerly, all of them, except the casting itself, were done by hand, and each type was handled separately, except in the operation of dressing, or the final finishing, where they were handled in lines of about three feet in length.

After the type have been delivered to the inspector, they are examined under a magnifying glass and all imperfect type are thrown out. The perfect type are then delivered to "fonting" room, where they are weighed, counted, and put up in suitable packages in proper proportion of one letter with another, ready for the printer.

Formerly the various sizes of type were indicated by names which had developed with the history of type making. It was a source of considerable annoyance to printers that these old standards were not accurate, and that two types of supposedly the same size, and sold under the same name, by different makers, varied so much that they could not be used side by side. Of recent years the "point" system, by which each size bears a proportionate relation to every other size, has done much to remedy this trouble, and now nearly all type is made on that basis. An American point is practically one seventy-second of an inch. Actually it is .013837 inch. It was based on the pica size most extensively in use in this country. This pica was divided into twelve equal parts and each part called a point. All the other sizes were made to conform to multiples of this point. The point is so near a seventy-second of an inch that printers frequently calculate the length of the pages by counting the lines, the basis being twelve lines of 6 point, nine lines of 8 point, eight lines of 9 point, and six lines of 12 point to the inch. This calculation is really quite accurate.

The following table will show the old and new names for the various sizes:--