Scoring and Perforating
Heavier Boards need to be scored before folding. Papers with weight over 170gsm should be scored to avoid the spine cracking. Scoring and perforating can either be done during printing or when die-cutting.
Die Cutting
If the job is an irregular shape (such as a folder with pockets) and cannot be guillotined it will need to be die cut. A form is made from sharp knives which are embedded in wood. The knives follow the shape of the outside of the folder. Blunt knives will crease and score. The form is then registered with the printed sheet and shape is punched out.
Die Stamping
Die stamping is a process which gives a raised printed image. It can be used on areas without ink to blind emboss. The image stands out in relief and is created using two dies, A 'male' and a 'female'. One die forces the paper into the other to make an embossed image.
Stitching
A form of binding using a wire staple or a thread stitch. Most brochures or leaflets with eight or more pages will be stitched with a staple.
Perfect Binding
Perfect bound books are trimmed on the spine and the pages glued in place. Most paperback books and thicker magazines are perfect bound.
Varnishing
Varnish is a sealant applied after printing, that can be gloss or matt (offline varnishing). Some printing presses can varnish at the same time as the print run (inline varnishing or aqua seal) although the effect is not as pronounced as offline varnishing. The varnish seals the ink into onto the paper so that it does not set off. Varnish can be printed in small areas for creative design effects (spot varnish), using a plate just as a colour would be printed. When a small amount of colour is mixed with the varnish, an interesting subtle effect can be obtained.
UV Varnish
This is a very high gloss varnish as it might be found on paperback covers. UV Varnish can also be printed in selected areas giving a 'spot lamination' look, although registration is more difficult than machine varnish and it should not be used if accuracy is essential. This form of varnishing is a cost-effective alternative to lamination. However it will crack when folded and this will be noticeable if colour is printed over fold areas.
Blocking
A metal die is pressed onto the material to be printed through metallic foil. Blocking is available in black, white or other colours, in addition to the traditional gold and silver.
Gluing, making up and collation
Folders with pockets have to be folded and glued by hand. All inserts will be collated by hand. Collation is charged for by each action, therefore the more pockets and the more inserts the higher the cost.
Lamination
This is a thick plastic coating which is heat sealed onto one side of the printed matter and can be gloss or matt. It can be expensive but provides a scuff-proofed quality finish.
Encapsulation
A finishing process where the printed sheet is heat sealed and sandwiched between two sheets of plastic. The plastic is available in various thicknesses. When finished the sheet has a non-removable, 3-5mm edge of plastic and its extremely durable.
Thermography
A glossy raised image in which the ink appears as a plastic coating. The raised surface is produced by fusing resinous powders, onto fresh ink, with heat. It is often used on stationery but can be used for more creative effects.
Ref - The Spy Guide to Design and Print, 655.31 Leeds College of Art, Blenheim Walk
Wikipedia:
Foil Blocking
Foil stamping, typically a commercial print process, is the application of pigment or metallic foil, often gold or silver , but can also be various patterns or what is known as pastel foil which is a flat opaque color or white special film-backed material, to paper where a heated die is stamped onto the foil, making it adhere to the surface leaving the design of the die on the paper. Foil stamping can be combined with embossing to create a more striking 3D image.
Embossing
Debossing
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