738:
elevator then descends to a position in front of the mold, and if the elevator has not descended fully by the time the machine starts the process of aligning the matrices (most often caused by a âtightâ line), the first of the two safeties, the vise automatic, brings the machine to a full stop before the supporting lugs on the matrices are crushed by the mold. Once the matrices are in proper position, two actions take place in sequence: the matrices are aligned vertically and face-wise while a bar rises from below to force the movable sleeves on the space bands upwards to cause them to fill out the line to the exact width of the mold. If the justification bar has made a full cycle and the line is still not fully justified, the second safety, the pump stop, prevents the plunger in the metal pot from going down. The space bands were an important feature of this machine, providing automatic justification of each line by equally adjusting the white space between each word. Since the type used was proportional and not fixed in width, solving this justification problem mechanically was very important. Some later models had a feature that permitted the lines to be cast with the alignment to either left, right or centered. Operators running earlier models would use special âblankâ matrices (in four sizes) to manually create the proper amount of whitespace beyond the space bandsâ range.
746:
slide onto the second elevator bar which carries the matrices by these V-shaped notches. The space bands, having no such notches, remain in the second transfer channel and are soon gathered by two levers and pushed back into the space band box. While the space bands are being pushed into their box, the second elevator continues rising towards the distributing mechanism at the top of the machine, which returns the molds to their proper places in the magazine. At the top of the machine, a lever (the distributor shifter) moves left to get in position to push the incoming line of matrices off the second elevator and into the distributor box. This mechanism feeds the matrices at precise intervals such that they travel between three rotating screws. Each matrix is carried along a notched bar between the three screws until the notches on the bar and matrix match, whereupon the matrix drops down into its proper channel in the magazine.
829:
considerable force, injecting molten type metal into the mold at a high speed to ensure the mold was filled before the metal solidified. If the stick was not properly filled out or mounted firmly, or the special terminating block was forgotten, a dreaded "splash" would result, often encasing the operator's toes in molten lead and leaving a mess that needed to be peeled off the Ludlow surfaces. Operators were encouraged to wear heavy boots with steel toes and be quick at removing one. It was also not uncommon for some of the type metal to be projected up onto the ceiling, no matter the height. As with the
Linotype / Intertype machines, the Ludlow machines were often fitted with metal feeders to keep the pot filled to optimum level.
758:
skimmed off. As part of this process, âplus metalâ is added in the form of small ingots to replenish that portion of the alloyed metals that was lost by the formation of dross (by oxidization of the metal in the machine's pot or during the remelting stage). The type metal is poured into ingot molds â small molds for manually feeding the metal pots or larger molds for the metal feeders. (In the latter case, special attention must be given the âeyeâ end as it has to support the weight of the entire ingot. Failure often results in it dropping into the pot and splashing molten metal everywhere.)
122:
742:
freshly cast slug), the metal pot, and the first elevator. The mold disk then turns to present the line at the ejecting position, in the process passing by a knife that trims the base of the slug to type height (0.918âł on US machines). The slug is then forced through an adjustable pair of knives to trim the slug to the proper body height before sliding down into a âgalleyâ of finished lines next to the operator. Depending on the model of machine, the mold disk could have four (standard), six, or two molds, giving the operator his choice of line lengths and body sizes.
152:
730:
other as the machine prepares for the casting operation. If the line is âtightâ or too long, the elevator carrying the matrices and space bands will not seat properly in front of the mold slot. Both the
Linotype and Intertype machines have two important safeties that act during the casting operation â the âpump stopâ, which comes into play on loose lines, and the âvise automatic', which comes into play on tight lines. Both scenarios, if not stopped by these safety features, usually result in a âsquirtâ of molten
875:
25:
1320:
887:
for subsequent editions. This was a popular system for book work. Text was produced completely aligned, with all spaces in each line exactly the same width. Corrections and complex work could be done on the text by hand after the bulk of the text had been set by machine. The Super Caster and Orphan Annie were used to cast fonts of loose type for hand setting as well as spacing material and patterned rules.
854:, 2, 3, 4, 6, 12, 18, 24, 30, or 36 point. This was used extensively in page layout and line spacing, that is, adjusting the white space between paragraphs and any other area when small bits of white space were needed. Large areas of white space were created by wooden or later metal blocks called 'furniture'. Smaller odd areas were filled with square or rectangular blocks in various point sizes called
734:, encasing the matrices and the elevator in metal in the process. Not only is it time-consuming to clean up after a squirt, a tight line usually has not come down far enough to mate with the slots on the mold face, resulting in damage to the matrices. Therefore, it is considered very poor form for an operator (or the machinist who cared for the machine) to permit this to happen.
789:'), but an electric pot was later developed and which became a standard option. As with the motors, the control machinery for the metal pot heaters was produced in a variety of voltages and in direct or alternating current versions. For locations with access to neither gas or electricity, the gas-fired pot could be fitted with a burner kit to allow the use of kerosene or other '
778:
powered from direct current, 25 Hz AC, or 50 Hz AC circuits. Also, motors wound for various polyphase circuits (two-phase, 3-phase, wye, delta, etc.) were made available for the customers as well. In a few cases, where electricity was not available, it was possible to drive the machine by a belt connected to a
678:
complete line of text with the usual character repetitions. Indeed, the nominal 90-channel magazine of a linecaster really has 91 total channels, with the first two channels allocated to the lower case 'e', and with these matrices being alternately selected from channel 0 or channel 1, for alternate lines of cast type.
939:
These tapes could be read and processed by many, maybe most optical setting systems. This allows avoiding actual use of metal, while preserving some of the value and investment in the "typesetting" and communication side of hot metal. Such systems were widely used in the later years of hot metal, and
890:
This type was most times made of an alloy (8-10% tin, 15-20% antimony) slightly harder than the line casting alloys but was not as hard as the foundry type used for hand setting of loose letters. This allowed reasonable print runs or conversion to stereotypes for longer print runs. But these machines
836:
type setter, the Ludlow was often joined by the "Super
Surfacer" a specially designed surface plane that would smooth the surface of the freshly cast type and ensure it was exactly type high. A Ludlow slug was just the letters overhanging a central spine about 12 points wide (T-shaped viewed from the
729:
Once the line approaches its correct length, the operator is made aware of this by a bell or other indicator. If the line is âlooseâ or too short, there is too much âwhite spaceâ for the space band wedges to fill out the line, and the matrices could possibly turn sidewise or fail to seal against each
697:
use a punched paper tape, although this option is seldom-used outside of daily newspapers, and whether a tape is used, or not, the "reading frame" is always forwards (left-to-right), with justification being an inherent capability of the machine (and, "flush right", "centered" and "flush left" may be
757:
From time to time, the slug galley is transferred to the composing table to be set in the form, and once the press run is completed and the slugs removed from the form, they are tossed into the âhell boxâ for remelting into new ingots. At intervals the lead is remelted and the oxidized metal (dross)
721:
Once a key is pressed, the matrix passes through what is known as the âassembler frontâ, down past a rotating fiber reinforced wheel (known as the star wheel) and into the âassembling elevatorâ which serves the same purpose as the hand compositor's stick. When the space band key near the keyboard is
886:
took a different direction in hot metal typesetting, with the ability of the
Composition Caster to cast loose type using a paper tape-operated automatic casting machine. The paper tape would be first generated on a keyboard and then used to cast the type; the tape could be stored for future casting
600:
Hot metal typesetting was developed in the late nineteenth century as a development of conventional cast metal type. The technology had several advantages: it reduced labour since type sorts did not need to be slotted into position manually, and each casting created crisp new type for each printing
820:
The Ludlow consisted of a very heavy metal table with a flat top about waist high and a depressed slot into which a "stick" was inserted. Underneath was a pot of molten type metal and a plunger. The stick was used to hand compose the lines of type, typically headlines in 18 point or larger with 72
753:
The metal pot was kept filled by the operator tossing in small ingots of type metal every few lines, or later, by mechanical feeders that carry large ingots of type metal (and which often carried two âpigsâ at a time to be consumed in turn, the operator hanging a fresh one when one was consumed).
745:
As the mold disk is turning, the first elevator simultaneously rises to its upper position and the space bands and matrices are vertically aligned in preparation for the second transfer. The matrices have a series of teeth in a V-shaped notch on top, and as the transfer is completed, the matrices
737:
When the line is assembled to the correct length, the operator presses down on a lever which raises the assembling elevator up into the delivery channel and starts the automatic casting cycle. The delivery channel transfers the matrices out of the assembler and into the first elevator. The first
677:
Another essential difference between
Monotype and the "slug"-producing machines is that a Monotype machine functions with a minimal set of matrices. Each character needs one matrix. Linecasters cannot function this way, and these systems need quite large magazines of matrices to be able to set a
777:
Various methods were used to power the
Linotype / Intertype machines, the most common being a fractional horsepower motor, one wired for single-phase 60 Hz alternating current eventually becoming the default offering. To accommodate the customers' requirements, motors were also built to be
741:
With the matrices aligned and the space bands set to the correct measure, the machine then âlocks upâ the line with great force and the plunger injects the molten type metal into the space created by the mold cavity and the assembled line. The machine then separates the mold disk (carrying the
673:
The success of these machines lay in different fields. The
Monotype caster was more popular for bookwork that required the ability to make manual corrections and edits while the slug casting systems found success in newspaper production, where speed of production and 'make ready' for print was
669:
the matrices for each line were assembled in a stick by hand. This machine was able to cast display body sizes that other mechanical composition systems were unable to produce. In this way headings could be produced to complement text produced on other machines. It also used the same alloy as
828:
After a line of type was assembled into the stick a special blocking slug was inserted to seal the end. Then the stick was placed mold side down into the slot on the table, a clamp locked down to securely hold the stick and the Ludlow activated. The plunger would snap down into the pot with
825:" used to set body type, but simpler alphabetically arranged wooden or metal cases, each one containing a given font in a specific size and style such as bold face, italic or condensed. The metal type cabinets were built with inclined drawers for easy access to the matrices.
717:
made of brass. The matrices are stored in one or more magazines on top of the machine (providing the operator with a choice of fonts; these can also be exchanged with other extra magazines as desired) while the space bands are stored in a box closer to the keyboard.
661:
The
Linotype and similar Intertype machines came out with paper tape and electronic automation near the end of their lifecycles, which allowed for the news wire services to send breaking news to remote newspaper offices for prompt setting into late editions.
960:
and misalignment. These disappointing results were a thorn in the sides of many authors and readers (especially of complex or mathematical texts that had many small sub- and superscripts). A desire to re-create the aesthetic qualities of hot lead spurred
796:
Thus, regardless of the power sources available (within reason), it was possible to install a
Linotype (or Intertype) machine in almost any newspaper office, whether in a remote mountain community or a downtown office in an urban metropolis.
670:
Linotype machines, so was a useful adjunct to page makeup for newspapers as, when a print run was completed, all the metal could be remelted at once, without having to be separated or the type from the headings redistributed back into case.
865:
point and which typically consisted of approximately 4% tin and 12% antimony and the balance being lead. These alloys were proportioned such that the type metal would solidify as rapidly as possible at the lowest possible freezing point.
837:
end). It needed to be bolstered by Elrod slugs on either side for support. The number of slugs above and below the central spine could adjust the white space above and below the type making it a very flexible system for large type.
749:
It was a source of pride for trained operators to boast of being able to âhangâ a line â to keep a line waiting in the delivery channel while the machine was casting the previous line and the operator was composing the next one.
754:
These feeders are actuated by various methods (by cam, either elevator, or distributor shifter), but the result is the same â the ingots are fed little by little into the pot, keeping it filled to the correct level.
821:
point commonly being available, but the machine could cast type from 4pt to 600pt without a mould change. This was from brass matrix stored in cases on either side of the Ludlow. The cases were not the traditional "
722:
pressed, one of the space bands drops out of the box and almost directly into the assembling elevator. The assembling elevator (or more commonly just the âassemblerâ) is adjustable for different lengths of line (in
624:
The Super-caster, another machine produced by
Monotype, was similar in function to the Thompson, Barth, pivotal and others casters but designed to produce single type (including even larger sizes) for hand setting.
894:
The used type, like the slugs from line casters, was re-melted when no longer needed. Each time remelting caused some loss of tin and antimony, through oxidation. This loss needed to be monitored and compensated.
773:
1914) a compatible version of the Linotype machine when the patents ran out and it became quite popular as well. This led to a long-lasting legal fight by the Mergenthaler Linotype Company (who eventually lost).
712:
The key feature of the Linotype is the use of molds which circulate through the machine in its various stages of operation. One type is a space band (a special two-part sliding wedge) and the other is a letter
910:
Towards the end of its life, hot metal composition in newspapers was kept alive by the proof press. As each page was set and locked up, it was moved on a turtle (a rolling table with an
617:
system, produced texts with the aid of perforated paper-ribbons. Each character was cast separately. These machines could produce texts also in "large-composition" up to 24
990:). The ensuing casting could be made curved for use on a rotary press or flat for the slower flat-bed presses. This technique was often used in newspaper production.
1073:
921:
Black paper was inserted before the proof was photographed for each of the photos on the final page to create clear windows in the negative. The separately made
1045:
940:
optical typesetting systems kept supporting and further developing TTS standard, alongside similar systems for most of the optical typesetting era.
1008:
925:
would be taped into these clear windows on the negative. This negative could then be used to expose the photosensitized printing plate for an
516:
914:
steel surface) to the manual proof press, where it was hand inked and a single very high quality proof was pulled. This proof could then be
936:
and transition mechanism was using paper tapes made for TTS systems (linotype) and monotype tapes directly by the photo typesetter system.
929:. In this way the heavy investment in hot metal typesetting could be adapted to the newer offset technology during a transition period.
817:
also met with success because it was able to cast display type sizes that other mechanical composition systems were unable to produce.
956:, a good fidelity to the original was achieved. Phototypesetting suffered (at least in its early days) from many problems relating to
89:
61:
585:
are later used to press ink onto paper. Normally the typecasting machine would be controlled by a keyboard or by a paper tape.
42:
1192:
613:
Two different approaches to mechanising typesetting were independently developed in the late 19th century. One, known as the
68:
605:, each line was cast as a robust continuous block (hence "line o'type") which was useful for rapid newspaper printing.
75:
1126:
509:
108:
588:
It was the standard technology used for mass-market printing from the late nineteenth century until the arrival of
952:
processes that followed it. As the lead type used to print (letterpress) a page had been directly formed from the
57:
46:
502:
685:
use a punched paper tape, and the "reading frame" is always backwards (right-to-left) in order to achieve
1244:
1185:
976:
or nickeltype) could be used to cast a reproduction of an entire typeset page (or pages imposed in a
463:
1019:
628:
The other approach was to cast complete lines as one slug, usually comprising a whole line of text.
948:
The nature of text printed via the hot-metal method is notably different from that produced by the
418:
82:
840:
The Elrod was a machine used to cast rules and spacing material (leading) of a specific width: 1,
1373:
35:
1555:
188:
1567:
1431:
1280:
766:
686:
640:
278:
121:
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1290:
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1201:
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1101:
899:
562:
328:
8:
1649:
1550:
1363:
1212:
957:
822:
646:
368:
143:
1504:
1358:
1353:
689:, as justification is not an inherent capability of the machine (however, "flush left"
618:
582:
578:
168:
1259:
987:
953:
723:
714:
570:
358:
338:
268:
1436:
1426:
1416:
1393:
1388:
1383:
949:
814:
731:
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very easily accommodated manually, or automatically using a "quadder" attachment).
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635:
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589:
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127:
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408:
348:
298:
238:
1562:
1523:
1450:
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915:
428:
388:
198:
902:
survived the demise of the hot metal typesetting era by selling digital type.
1643:
1597:
1540:
1300:
973:
911:
878:
A Monotype composition case showing bronze matrices struck from steel punches
762:
1074:"Making headlines: printing the Guardian newspaper, 1921-1987 - in pictures"
770:
1592:
1533:
1305:
1236:
1160:
1078:
1050:
962:
178:
1130:
1628:
1623:
1618:
1328:
1254:
1046:"The end of hot metal printing: GNM Archive teaching resource March 2015"
965:
to create one of the first general-purpose digital typesetting programs,
874:
665:
While the other machines were operated by (non-QWERTY) keyboards, in the
558:
473:
258:
1613:
1494:
1249:
1170:
779:
566:
534:
378:
318:
288:
977:
1343:
1264:
1165:
805:
These machines were bought out by Linotype, to minimize competition.
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453:
228:
24:
1499:
1319:
922:
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833:
786:
530:
248:
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Initially, the metal pot was heated by gas (whether natural or '
1475:
1465:
1285:
982:
861:
All these line-casting machines used various alloys near the
855:
574:
1093:
1000:
1155:
891:
could produce type with all possible alloys, when needed.
966:
631:
Of this system there were at least five manufacturers:
1161:
Linotype & Ludlow Working Museums â Denmark, Iowa
592:
and then electronic processes in the 1950s to 1980s.
972:
Although not technically typesetting, stereotyping (
49:. Unsourced material may be challenged and removed.
1641:
1186:
980:) using a mold made with an impression using
510:
16:Mechanical analog method for text composition
1099:
1037:
943:
813:A manual linecasting solution known as the
1193:
1179:
693:an inherent capability). Whereas Linotype
517:
503:
150:
800:
109:Learn how and when to remove this message
1200:
1043:
873:
832:Towards the end of its life as a common
120:
1100:Kupferschmid, Indra (9 November 2012).
1071:
1016:Journal of the Printing History Society
608:
1642:
1166:National Print Museum, Dublin, Ireland
1065:
1174:
1006:
47:adding citations to reliable sources
18:
13:
1129:. Pressed for Time. Archived from
1072:Golding, Emma (18 November 2016).
657:The Monoline, a very basic machine
573:that has the shape of one or more
14:
1666:
1149:
125:Row of Linotype operators at the
1318:
23:
1102:"Cold type vs. hot typesetters"
1044:Narewska, Elli (3 March 2015).
1009:"Monotype and Phototypesetting"
34:needs additional citations for
1119:
1:
993:
918:and converted to a negative.
905:
565:. This method injects molten
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218:
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7:
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701:
615:Monotype composition caster
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705:
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1316:
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1208:
1127:"A Few Words About Words"
808:
765:newspaper interests, the
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472:
464:Thermal-transfer printing
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1156:British Printing Society
944:Comparison to successors
339:Photostat and rectigraph
1018:: 57â77. Archived from
681:Additionally, Monotype
138:Part of a series on the
58:"Hot metal typesetting"
879:
801:Typograph and Monoline
761:Funded largely by the
557:) is a technology for
543:mechanical typesetting
189:Intaglio (printmaking)
132:
1546:Golding & Company
1409:Hot metal typesetting
1007:Boag, Andrew (2000).
877:
767:Intertype Corporation
649:, produced in Germany
641:Intertype Corporation
539:hot metal typesetting
309:Hot metal typesetting
124:
1551:Chandler & Price
1291:Logographic printing
1202:Letterpress printing
900:Monotype Corporation
823:California Job Cases
609:Types of typesetting
601:job. In the case of
563:letterpress printing
547:hot lead typesetting
329:Daisy wheel printing
43:improve this article
1213:History of printing
1133:on 12 December 2003
369:Dot matrix printing
144:History of printing
1505:Composition roller
1337:Manual typesetting
958:optical distortion
880:
454:Solid ink printing
169:Woodblock printing
133:
1637:
1636:
1576:
1575:
1445:
1444:
1432:Intertype Machine
1314:
1313:
1274:Blocks and plates
603:Linotype machines
527:
526:
492:
491:
359:Spirit duplicator
269:Chromolithography
119:
118:
111:
93:
1662:
1514:Types of presses
1459:Parts of a press
1456:
1455:
1437:Paige Compositor
1427:Ludlow Typograph
1417:Linotype machine
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1333:
1322:
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1232:
1195:
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1058:
1041:
1035:
1034:
1032:
1030:
1025:on 28 March 2016
1024:
1013:
1004:
950:phototypesetting
853:
852:
848:
845:
815:Ludlow Typograph
708:Linotype machine
667:Ludlow Typograph
653:Ludlow Typograph
590:phototypesetting
577:. The resulting
519:
512:
505:
484:Digital printing
448:
445:
439:Thermal printing
399:Phototypesetting
223:
220:
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154:
135:
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128:Chicago Defender
114:
107:
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19:
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1665:
1664:
1663:
1661:
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1659:
1640:
1639:
1638:
1633:
1602:
1588:Folding machine
1581:Other equipment
1572:
1509:
1483:
1441:
1422:Monotype system
1403:
1349:Composing stick
1323:
1310:
1269:
1228:
1222:
1204:
1199:
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1125:
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1038:
1028:
1026:
1022:
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1005:
1001:
996:
946:
912:accurately flat
908:
884:Monotype System
872:
850:
846:
843:
841:
811:
803:
710:
704:
611:
598:
523:
494:
493:
446:
419:Dye-sublimation
409:Inkjet printing
349:Screen printing
299:Offset printing
239:Relief printing
221:
206:
162:
131:newspaper, 1941
115:
104:
98:
95:
52:
50:
40:
28:
17:
12:
11:
5:
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1565:
1563:Cylinder press
1560:
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1451:Printing press
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1296:Wood engraving
1293:
1288:
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1270:
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54:Find sources:
48:
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38:
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32:This article
30:
26:
21:
20:
1610:Related arts
1593:Paper cutter
1568:Rotary press
1408:
1306:Zinc etching
1245:Type casting
1237:Movable type
1227:Ways to make
1135:. Retrieved
1131:the original
1121:
1109:. Retrieved
1105:
1095:
1083:. Retrieved
1079:The Guardian
1077:
1067:
1055:. Retrieved
1051:The Guardian
1049:
1039:
1027:. Retrieved
1020:the original
1015:
1002:
988:papier-mâchÊ
986:(similar to
981:
971:
963:Donald Knuth
947:
938:
931:
927:offset press
920:
916:photographed
909:
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819:
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795:
787:manufactured
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279:Rotary press
179:Movable type
126:
105:
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65:
53:
41:Please help
36:verification
33:
1655:Typesetting
1629:Papermaking
1624:Printmaking
1619:Bookbinding
1520:Hand press
1329:Typesetting
1301:Electrotype
1255:Punchcutter
1229:impressions
1106:Alphabettes
974:electrotype
954:type matrix
769:developed (
674:essential.
559:typesetting
474:3D printing
447: 1972
259:Lithography
222: 1515
207: 1440
1650:Typography
1644:Categories
1614:Typography
1495:Offset ink
1281:Stereotype
1250:Type metal
994:References
906:Transition
780:line shaft
732:type metal
567:type metal
535:typography
379:Xerography
319:Mimeograph
289:Hectograph
161:Techniques
69:newspapers
1529:Columbian
1374:Furniture
1344:Type case
1265:Wood type
1111:20 August
1085:20 August
1057:20 August
923:halftones
793:' fuels.
791:white gas
647:Typograph
551:hot metal
229:Mezzotint
1524:Stanhope
1500:Ink ball
932:Another
870:Monotype
863:eutectic
834:backshop
702:Linotype
636:Linotype
561:text in
555:hot type
531:printing
249:Aquatint
1471:Frisket
1399:Hellbox
1379:Leading
1218:Printer
1029:22 July
934:synergy
849:⁄
596:History
569:into a
214:Etching
83:scholar
1534:Albion
1488:Inking
1476:Tympan
1466:Platen
1369:Reglet
1260:Matrix
809:Ludlow
763:Ridder
715:matrix
575:glyphs
553:, and
85:
78:
71:
64:
56:
1394:Forme
1389:Chase
1384:Quoin
1364:Strut
1286:Flong
1137:9 May
1023:(PDF)
1012:(PDF)
983:flong
978:forme
856:quads
724:picas
619:point
583:slugs
579:sorts
90:JSTOR
76:books
1359:Slug
1354:Sort
1139:2014
1113:2017
1087:2017
1059:2017
1031:2016
898:The
882:The
683:must
645:the
571:mold
533:and
488:1991
478:1986
468:1981
458:1972
433:1969
423:1957
413:1950
403:1949
393:1940
383:1938
373:1925
363:1923
353:1911
343:1907
333:1889
323:1885
313:1884
303:1875
293:1860
283:1843
273:1837
263:1796
253:1772
243:1690
233:1642
193:1430
183:1040
62:news
1480:Bed
967:TeX
726:).
695:may
581:or
529:In
173:200
45:by
1646::
1104:.
1076:.
1048:.
1014:.
969:.
858:.
782:.
771:c.
691:is
621:.
549:,
545:,
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219:c.
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1194:e
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1089:.
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