Class: Senior Secondary School 1 (SS1 / SSS 1)
Term: 2nd Term
Week: 2
Age: 15 years
Duration: 45 minutes
Subject: Printing Craft
Curriculum Theme: Trade
Previous Lesson: Printing Processes: Letterpress Relief Printing And Offset Lithography.
Topic: PRINTING PROCESSES (CONT)
Subject Matter: Gravure and intaglio printing, Screen and stencil printing, Flexography printing, Typical products for each process, Tools and materials overview

Specific Objectives

By the end of the lesson, pupils should be able to:

Cognitive Domain:

Define Gravure, Screen, and Flexography printing processes.
Describe the working principles of each process.
Identify typical products made using each printing method.

Affective Domain:

Appreciate the importance of different printing processes in daily life.
Value the precision required in printing craft.

Psychomotor Domain:

Identify the tools and materials used in Gravure, Screen, and Flexography printing.
Relate specific tools to their respective printing processes.

Participate actively in class discussions about various printing technologies.

Reference Materials

The following resources were used in planning this lesson:

9 Years Basic Education Curriculum for Printing Craft (Senior Secondary Education)
State Unified Scheme of Work for Printing Craft SSS 1
Printing Technology by J. Michael Adams

Instructional Materials

The teacher will teach this lesson with the aid of:

Screen frame
Squeegee
Flexo plate sample
Image of a gravure cylinder
Ink containers
Whiteboard and markers/chalk

Rationale for the Lesson

Understanding different printing processes helps pupils to know how various printed materials around them are produced. It also exposes them to different career paths and technological applications in the printing industry.

Prerequisite/Previous Knowledge

Pupils have a basic understanding of what printing is and may have been introduced to other simple printing processes in previous lessons.

Lesson Content/Board Summary

PRINTING PROCESSES (CONT.)

Gravure and Intaglio Printing

Gravure printing is an intaglio printing process where the image is etched or engraved onto a cylinder. The image areas are recessed (depressed) below the non-image areas.

The process involves the cylinder rotating in an ink fountain, filling the recessed image cells with ink. A doctor blade then scrapes off excess ink from the non-image surface. The substrate (paper or film) is pressed against the cylinder by an impression roller, transferring the ink from the cells to the substrate.

The following are characteristics of Gravure printing:

Excellent for high-volume, long-run jobs.
Produces high-quality, continuous-tone images.
Uses fast-drying, low-viscosity inks.

Screen and Stencil Printing

Screen printing, also known as serigraphy, is a stencil printing method where ink is forced through a mesh screen onto a substrate. A stencil is created on the screen, blocking the ink from passing through non-image areas.

The process involves placing the screen over the substrate. Ink is applied to the top of the screen and a squeegee is used to push the ink through the open mesh areas of the stencil onto the material below.

The following are characteristics of Screen printing:

Versatile; can print on various materials (textiles, paper, plastic, metal).
Allows for thick ink deposits, resulting in vibrant colors.
Suitable for both short and long runs.

Flexography Printing

Flexography is a relief printing process using a flexible relief plate. The image areas on the plate are raised above the non-image areas.

The process involves ink being transferred from an anilox roller to the raised image areas of the flexible printing plate. The plate then rotates and presses against the substrate, transferring the ink to create the image.

The following are characteristics of Flexography printing:

High speed, suitable for continuous patterns and large quantities.
Uses fast-drying inks.
Commonly used for packaging materials.

Typical Products for Each Process

The following are typical products for each printing process:

Gravure Printing: Magazines, catalogues, packaging (flexible packaging, food wrappers), gift wrap, wallpaper, high-volume security printing.
Screen Printing: T-shirts and textiles, posters, banners, stickers, circuit boards, glass, ceramic decals, promotional items.
Flexography Printing: Labels, flexible packaging (plastic bags, food packaging), corrugated cardboard, newspapers, milk cartons, disposable cups.

Tools and Materials Overview

The following are common tools and materials for these printing processes:

Gravure: Engraved cylinders, doctor blade, impression roller, gravure inks, various substrates (film, paper).
Screen Printing: Screen frame (wooden or aluminum), mesh (polyester, nylon), squeegee, stencil material (emulsion), exposure unit, screen printing inks, various substrates (fabric, paper, plastic).
Flexography: Flexible printing plates (photopolymer), anilox roller, impression cylinder, plate cylinder, flexo inks, various substrates (film, foil, paper, corrugated).

Teaching Methods/Instructional Techniques

Discussion, Lecture, Demonstration, Question and Answer, Visual Aids

Instructional Procedures

Step 1: Introduction

Time: 5 minutes
Teaching Skill: Set Induction
Teacher’s Activity: The teacher greets the pupils and reviews the previous lesson briefly. The teacher then introduces the new topic, “Printing Processes (Cont.)”, by asking pupils to mention different printed items they see daily and how they think these items are made.
Pupils’ Activity: Pupils respond to the teacher’s questions and listen attentively.
Learning Point: Pupils are prepared for the new lesson and connect it to their environment.

Step 2: Gravure and Intaglio Printing

Time: 10 minutes
Teaching Skill: Explanation/Demonstration
Teacher’s Activity: The teacher explains Gravure printing, describing its principle as an intaglio process where the image is recessed. The teacher uses an image of a gravure cylinder to illustrate how ink is held in the cells and transferred. The teacher also lists typical products.
Pupils’ Activity: Pupils listen, observe the image, and ask questions for clarity. They take notes.
Learning Point: Pupils understand the concept and application of Gravure printing.

Step 3: Screen and Stencil Printing

Time: 8 minutes
Teaching Skill: Explanation/Demonstration
Teacher’s Activity: The teacher explains Screen printing, describing it as a stencil method. The teacher demonstrates with a screen frame and squeegee how ink is forced through the mesh. The teacher highlights its versatility and typical products.
Pupils’ Activity: Pupils observe the demonstration, listen to the explanation, and identify the materials shown. They take notes.
Learning Point: Pupils understand the process and uses of Screen printing.

Step 4: Flexography Printing

Time: 7 minutes
Teaching Skill: Explanation/Illustration
Teacher’s Activity: The teacher explains Flexography printing as a relief printing process using flexible plates. The teacher describes how ink is transferred from anilox rollers to the raised image areas and then to the substrate, showing a flexo plate sample. The teacher mentions its speed and common products.
Pupils’ Activity: Pupils listen, observe the sample, and understand the mechanism of Flexography. They take notes.
Learning Point: Pupils grasp the concept and applications of Flexography printing.

Step 5: Typical Products and Tools Overview

Time: 5 minutes
Teaching Skill: Listing/Consolidation
Teacher’s Activity: The teacher consolidates the information by listing typical products for each process discussed. The teacher also summarizes the key tools and materials associated with Gravure, Screen, and Flexography printing, showing ink containers as a general material.
Pupils’ Activity: Pupils listen and confirm their understanding of products and tools for each process.
Learning Point: Pupils can distinguish products and tools specific to each printing method.

Step 6: Evaluation/Review

Time: 5 minutes

Teaching Skill: Questioning/Assessment

Teacher’s Activity: The teacher evaluates the learning by asking the following questions:

Define Gravure printing.
List three characteristics of Screen printing.
Mention two products typically produced using Flexography printing.
Identify one key tool used in Gravure printing and one in Screen printing.

Pupils’ Activity: Pupils answer orally and in writing.

Learning Point: Pupils demonstrate understanding of the lesson.

Step 7: Conclusion

Time: 5 minutes
Teaching Skill: Summarization/Assignment
Teacher’s Activity: The teacher summarizes the key points of the lesson, reiterating the different printing processes, their principles, and common applications. The teacher gives an assignment: “Research and write down two advantages and two disadvantages for each of the printing processes discussed today.”
Pupils’ Activity: Pupils listen to the summary and copy the assignment.
Learning Point: Pupils consolidate their learning and are given tasks for further study.

Lesson Keywords

Gravure – An intaglio printing process where the image is etched onto a cylinder.
Intaglio – A printing technique where the image is incised into a surface.
Screen Printing – A stencil method where ink is forced through a mesh screen onto a substrate.
Flexography – A relief printing process using flexible plates with raised image areas.
Squeegee – A tool with a rubber blade used in screen printing to force ink through the mesh.
Anilox Roller – A roller used in flexography to transfer a uniform layer of ink to the printing plate.

Differentiation

The teacher will provide additional visual aids and simplified explanations for pupils who may struggle with abstract concepts. More complex examples and extensions will be offered to advanced learners to deepen their understanding.

Note for teachers using this lesson plan

Ensure all instructional materials are prepared and easily accessible before the lesson begins. Encourage pupils to relate the printing processes to real-world examples they encounter daily. Practical demonstrations, even simple ones, can significantly enhance understanding.