How we do it

The process of producing pop-up books or any pop-up item is a complex one. In the case of a book, it all starts like any other kind of book, with an idea. The pop-up content is decided upon with author, editor and designer and then the pop-up designer or paper engineer can begin work.

A pop-up dinosaur standing on part of the cutter trace outlining the pieces that go to form him.

The piles of printed paper shown here at the printing plant represent a small proportion of a recent book. These printed sheets amount to about 16,000 copies of a 200,000 copy run.

The paper engineer gathers images of the subject to be 'popped' from as many angles as possible. In the case of a building or machine, plans are invaluable. A prototype is roughly made from white card, this is then taken apart and a cutter trace is made. Further prototypes are made and fine tuned until the pop works perfectly.

The final prototype, along with accurate cutter traces, is given to an illustrator to artwork. Final artworks are scanned, digitally proofed and assembled to check if they work.

The scanned pieces are then laid out like a jigsaw on large sheets to use the most efficient amount of card. The digital files are sent on disc to a specialist printer.

From the disc the printer is able to print the book and make a cutter for the pop up pieces. This can be done by lazer or by hand and is a very skilled task. The printed pop-up piece sheets are then passed through a cutting machine one at a time. The pop up elements are assembled by hand and combined with the pages to make a complete book.

Up to 2000 people can be employed to assemble a pop-up book edition. All the people work in good conditions. Hawcock Books work only with manufacturers that are fully accredited by U.S. inspectors.

For more information on how we produce Pop-up books, you can download our Specially produced PDF (1MB). We regret that no further information can be provided.