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ands range with the matrices aligned and the space bands set to the correct measure the machine then locks up 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 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 0 918 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 galley 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 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 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 it was a source of pride for trained operators to boast of being able to hang a line 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 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 pigs at a time to be consumed in turn the operator hanging a fresh one when one was consumed these feeders are actuated by various methods by cam either elevator or distributor shifter but the result is the same the ingots are fed little by little into the pot keeping it filled to the correct level 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 hell box for remelting into new ingots at intervals the lead is remelted and the oxidized metal dross skimmed off as part of this process plus metal 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 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 eye 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 funded largely by the ridder newspaper interests the intertype corporation developed c 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 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 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 line shaft initially the metal pot was heated by gas whether natural or manufactured 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 white gas fuels 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 typograph and monoline edit these machines were bought out by linotype to minimize competition ludlow edit a manual linecasting solution known as the ludlow typograph also met with success because it was able to cast display type sizes that other mechanical composition systems were unable to produce 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 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 california job cases 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 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 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 towards the end of its life as a common backshop 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 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 the elrod was a machine used to cast rules and spacing material leading of a specific width 1 1 1 2 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 quads all these line casting machines used various alloys near the eutectic 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 monotype edit a monotype composition case showing bronze matrices struck from steel punches the monotype system 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 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 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 could produce type with all possible alloys when needed 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 the monotype corporation survived the demise of the hot metal typesetting era by selling digital type transition edit 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 accurately flat steel surface 5 to the manual proof press where it was hand inked and a single very high quality proof was pulled this proof could then be photographed and converted to a negative 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 halftones would be taped into these clear windows on the negative this negative could then be used to expose the photosensitized printing plate for an offset press in this way the heavy investment in hot metal typesetting could be adapted to the newer offset technology during a transition period another synergy and transition mechanism was using paper tapes made for tts systems linotype and monotype tapes directly by the photo typesetter system 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 optical typesetting systems kept supporting and further developing tts standard alongside similar systems for most of the optical typesetting era comparison to successors edit the nature of text printed via the hot metal method is notably different from that produced by the phototypesetting processes that followed it as the lead type used to print letterpress a page had been directly formed from the type matrix a good fidelity to the original was achieved phototypesetting suffered at least in its early days from many problems relating to optical distortion 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 donald knuth to create an early general purpose digital typesetting programs tex although not technically typesetting stereotyping electrotype or nickeltype could be used to cast a reproduction of an entire typeset page or pages imposed in a forme using a mold made with an impression using flong similar to papier mâché 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 references edit boag andrew 2000 monotype and phototypesetting pdf journal of the printing history society 57 77 archived from the original pdf on 28 march 2016 retrieved 22 july 2016 narewska elli 3 march 2015 the end of hot metal printing gnm archive teaching resource march 2015 the guardian retrieved 20 august 2017 golding emma 18 november 2016 making headlines printing the guardian newspaper 1921 1987 in pictures the guardian retrieved 20 august 2017 kupferschmid indra 9 november 2012 cold type vs hot typesetters alphabettes retrieved 20 august 2017 a few words about words pressed for time archived from the original on 12 december 2003 retrieved 9 may 2014 external links edit british printing society linotype ludlow working museums denmark iowa national print museum dublin ireland v t e letterpress printing history of printing printer movable type type casting type metal punchcutter matrix wood type blocks plates stereotype flong logographic printing wood engraving electrotype zinc etching typesetting manual type case composing stick sort slug strut reglet furniture leading quoin chase forme hellbox hot metal linotype monotype ludlow typograph intertype paige compositor printing press parts platen frisket tympan bed inking offset ink ink ball composition roller types hand stanhope columbian albion jobbing golding company chandler price colt s armory cylinder rotary other items folding machine paper cutter addressograph related typography bookbinding printmaking papermaking authority control databases gnd retrieved from https en wikipedia org w index php title hot_metal_typesetting oldid 1368110589 categories printing technology typography typesetting hidden categories articles with short description short description matches wikidata articles needing additional references from september 2014 all articles needing additional references this page was last edited on 7 august 2026 at 02 21 utc page was rendered with parsoid text is available under the creative commons attribution sharealike 4 0 license additional terms may apply by using this site you agree to the terms of use and privacy policy wikipedia is a 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