The sequence of events can vary slightly, and usually the entire sequence does not occur in one continuous pass through a binding line. What has been described above is unsewn binding, now increasingly common. The signatures of a book can also be held together by Smyth sewing. Needles pass through the spine fold of each signature in succession, from the outside to the center of the fold, sewing the pages of the signature together and each signature to its neighbors. McCain sewing, often used in schoolbook binding, involves drilling holes through the entire book and sewing through all the pages from front to back near the spine edge. Both of these methods mean that the folds in the spine of the book will not be ground off in the binding line. This is true of another technique, notch binding, where gashes about an inch long are made at intervals through the fold in the spine of each signature, parallel to the spine direction. In the binding line glue is forced into these “notches” right to the center of the signature, so that every pair of pages in the signature is bonded to every other one, just as in the Smyth sewn book. The rest of the binding process is similar in all instances. Sewn and notch bound books can be bound as either hardbacks or paperbacks.

Making cases happens off-line and prior to the book’s arrival at the binding line. In the most basic case making, two pieces of cardboard are placed onto a glued piece of cloth with a space between them into which is glued a thinner board cut to the width of the spine of the book. The overlapping edges of the cloth (about 5/8” all round) are folded over the boards, and pressed down to adhere. After case making the stack of cases will go to the foil stamping area. Metal dies, photoengraved elsewhere, are mounted in the stamping machine and rolls of foil are positioned to pass between the dies and the case to be stamped. Heat and pressure cause the foil to detach from its backing and adhere to the case. Foils come in various shades of gold and silver and in a variety pigment colors, and by careful setup quite elaborate effects can be achieved by using different rolls of foil on the one book. Cases can also be made from paper which has been printed separately and then protected with clear film lamination. A three-piece case is made similarly but has a different material on the spine and overlapping onto the sides: so it starts out as three pieces of material, one each of a cheaper material for the sides and the different, stronger material for the spine.

Recent developments in book manufacturing include the development of digital printing. Book pages are printed, in much the same way as an office copier works, using toner rather than ink. Each book is printed in one pass, not as separate signatures. Digital printing has permitted the manufacture of much smaller quantities than offset, in part because of the absence of make readies and of spoilage. One might think of a web press as printing quantities over 2000, quantities from 250 to 2000 being printed on sheet-fed presses, and digital presses doing quantities below 250. These numbers are of course only approximate and will vary from supplier to supplier, and from book to book depending on its characteristics. Digital printing has opened up the possibility of print-on-demand, where no books are printed until after an order is received from a customer.