Tuesday, April 27, 2021

Shark Card Jawsome Pop Up

Fun interactive 5x7 card opens to reveal pop up 
dimensional shark head and jaws chomp together 
to echo the front cover’s playful declaration to 
“Have a very JAWSOME Birthday”. 
(Alternative shapes included for Mother’s Day version.) 
Card front has two offset accent panels, 
JAWSOME overlay letters, and offset base for 
front accent layer; back has stylized oval 
to print or pen a sentiment. Interior accent panel includes 
slots for shark pop-up mechanism structures 
(separate head, tongue, jaw), plus dorsal and side fins. 
Add optional interior word cuts that finish the phrase 
“to the very last BITE”. 
Companion design “Envelope Shark Fin Waves” 
is also available to enclose and deliver this special card.

ASSEMBLY: 1. Identify and cut the shapes for the card front
and word cut outs:
A main card base   B front accent shape base
C front accent panel with shark fin & waves cutout
D word cutout offset base
E word cutout base   F JAWSOME letter overlays
G back accent shape base  H back accent panel
I opt. back sentiment plaque
2. Identify and cut the shapes for the card interior
and pop up shark:
J interior card base with center perforation, slots
J1 shark mouth interior shape   J2 dorsal fin shape
K shark head main shape
(Shapes L-N, Q-R, U-V, S have LEFT and RiGHT shapes
to form the shark body, lower jaw, side fins.)
L shark side head underlay with side tab
M upper teeth underlay N mouth inside underlay
O tongue shape   P opt. top ctr accent shapes
Q lower teeth underlay  R law inside underlay
S eye white circle and interior pupil
T jaw main shape
U side fin base   V side fin contrast accent overlay
W "to the very last BITE" word cuts
X BITE welded word overlay
3. Prepare the card front base by positioning and attaching
front and back accent base shapes to the cover
right and left halves with offset margins, and contrast overlays
on top, with offset margins all around.
NOTE: the opt. sentiment shape can be written or printed
on prior to attaching. Otherwise, position and attach
on center of back panel half.
NOTE: non-liquid adhesive is recommended, such as
spray adhesive or thin double-sided adhesive tape.
If using liquid adhesive, it is strongly suggested that
this assembly be pressed under a heavy weight for
several hours to ensure the card main shapes
do not warp or curl as liquid glue dries.
4. Position and attach the "Have a totally JAWSOME
Birthday" (or " . . . Mother's Day) welded word shape
to the offset base, centering within the cut edges
as shown.  Position and attach each letter of
"JAWSOME" on top.
 Press under a flat weight such as this thick book
if using liquid adhesive.
5. Position and attach the assembled message shape
onto the front of the card accent panel, centered
between the fin/waves cutout and the bottom of panel.
6. Prepare the shark head shape by bending back
("valley" folds) on all perforations for head panels,
snout tab. NOTE: let the eye half circle cut edges
pop up without bending - there is NO perforation line there.
7. Assemble the two-part eyes by centering and attaching
the black pupil circle in the middle of the white eye circle
for each of two eyes.
Position and attach each eye over the circle cutouts,
with the upper half on the pop up portion, the lower
half on the shark head portion.
8. Bend the shark head shape to bring together
the snout edges so that the plain straight edge
overlaps the opposite tab to perforation.
Adjust so that bottom edges match up, and glue in place.
NOTE that you may need to insert a flat pointy tool
such as this spatula inside and under the tab seam
to help press against the tab underneath to make
sure it gets glued together well.
9. Assemble the side head underlay units by
applying glue to the backside of the side head underlay
(leave side tab free of glue at this point), then 
positioning teeth UNDER, and aligning edges that
should match up, leaving teeth exposed beyond
curvy edge. Complete for left and right units.
Here is what the unit looks like at this stage.
10. Turn the unit face down, then position and attach
the inside mouth shape along the lower portion,
with curvy edge matched to outer head curvy edge
(where the two edges actually match, and where
the curve of the teeth will still show through;
also match up the front snout edges.
11. Prepare to insert and attach the underlay units
to the inside surfaces of the main head shape
by identifying the glue boundary cut dash line, then . . . 
. . . apply glue above the line to curve edge, front snout
edge, and top, BUT leave the glue OFF of the side tab.
Insert the underlay unit under the head edge
and push into position snugly along front snout 
and top of head, and press in place.
12. Repeat for the other side underlay unit.
13. With both underlay units in place (or one by one)
it is possible to flatten the head shape on a table top
so that finger pressure can be applied to help
 the underlay units attach completely, as shown.
14. Prepare the jaw shape by bending center fold
as "mountain" fold, and tab folds as "valley" folds.
15. Identify the "downward" arrow symbol on the lower teeth
shape, which shows how that corner will point
toward bottom corner . . . 
. . . near center when the teeth
 shape is positioned onto the jaw segments as an underlay.
Apply glue to the backside of the jaw, in one area,
then fit the teeth over it and glue in place.
Repeat for the opposite side of jaw and second teeth
shape, then . . . 
. . . quickly fold the jaw shape along center perforation line
to make sure it will fold completely without interference.
(If there is interference, adjust the teeth slightly away
from the center perforation, if possible.)
16. Position and attach the inside mouth jaw shapes
over the top of the teeth underlays and glue in place
similarly to the teeth shapes. Fold to make sure
the jaw can be easily folded completely flat.
Here is the completed lower jaw shape.
17. Prepare the side fins by positioning and gluing
the contrast lower crescent over the lower inside edges
of the larger side fin shape.
18. Prepare the tongue main shape by bending
along center, and bend back tabs upward.
Position and attach the contrast tongue accent shape
halves along the perforation line, and . . .
. . . fold and press in half to make sure it will
easily be able to conform to the way the pop up needs to work.
19. Prepare the optional interior phrases by positioning
and gluing the BITE word on top of the "last BITE"
word cut.
20. Prepare the interior card panel by bending
along the center perforation line as "valley" fold.
21. Prepare to position and attach the inner mouth shape
by first bending as "valley" fold, then locate the tongue slots
on inner mouth and corresponding slots on inner card base.
Position and attach inner mouth shape onto panel,
taking care to line up center perforations of each
(snugly fit mouth shape crease into the fold of panel),
and also making sure the slots align so tabs can fit in.
22. Bend the dorsal fin shape along center perforation line
in similar way to inner mouth, then position so that it
touches top edge of inner mouth, folds fit together snugly,
and left side edge of fin rides along the center perforation
of inner panel . . .
. . . so panel will still be able to fold easily.
23. Preview where the interior phrase shapes will be
attached, beginning with the "last BITE" portion
which should be just a little above the bottom edge
of panel, with 'l' of "last" fairly close to center fold.
Then match the bottom edges of "to the very" to be
even with "last" bottom edges; also the distance away
from center fold should be balanced or even.
24. Begin the pop up shark assembly by inserting the tabs
of tongue into tongue slots (through inner mouth shape)
(NOTE that the tongue shape as viewed in this frame
shows the backside) . . .
. . . then on the panel's backside, bend the tabs UP
and glue in place.
25. Position and insert the tabs of the jaw into the lower pair
of slots, and . . . 
. . . on the backside, bend the tabs DOWN and
glue in place.
As each of the pop up shapes is attached, quickly make sure
that the card will be able to fold easily by folding 
and creasing along center perforation and . . . 
. . . assisting shapes and tabs to
"self adjust" as may be necessary.
26. Position the head assembly and insert the side tabs
through the slots, then . . .
. . . on the backside, bend tabs toward SIDES 
and glue in place.
From the front, apply fingertip pressure at sides of head
to make sure tabs attach completely.
27. Position the side fin assembly snugly along the side 
of the head, matching up the edges of the contrast on
fin and head, and glue in place. Repeat for other side fin.
Here is the interior panel with pop up and fins attached.
28. Fold the panel in half then apply double-sided adhesive
tape to one side/half of panel on backside, at outer edges
and next to center perforation; add some tape in middle, too.
Then position the folded panel onto the backside of front panel
assembly, taking care that center folds will fit snugly
together, and apply pressure.
29. Apply adhesive tape to the remaining panel half,
open panel, adjust to make sure center folds are snug,
and apply pressure to fully attach in place.
30. Fold card and apply pressure to lock in creases . . .
. . . and make sure that the pop up mechanism functions.
NOTE: this is a very thick card, and will NOT remain
neatly folded flat - this is natural and the way it must be.
Here is the finished card. First closed . . . 
. . . and opened.
31. To help "deliver" the thick card, consider either
enclosing in the companion envelope, or . . . 

. . . , fit into a clear plastic card holder cellophane envelope, or
cut a 2-3" wide strip from a thick household plastic storage
bag, and wrap around the closed card, overlap, trim, and . . .
. . . hold closed with a sticker circle.