Finally, in the 1880s in the United States, German-born Ottmar Mergenthaler invented the Linotype, a typecasting compositor that cast a solid one-piece line, or slug, from movable matrices of each letter. Each of the matrices was individually notched so that it could return only to its proper slot in the magazine after use. Justification was carried out by inserting wedged spacebands between groups of matrices immediately after making up the words of a given line. Here the matrices rather than type pieces went through the four basic operations of letterpress composition; cast lead was used for printing. The Linotype can produce the equivalent of 5,000 to 7,000 pieces of type per hour.

In 1885, also in the United States, Tolbert Lanston invented the Monotype, which casts individual pieces of type for a line and justifies each line by a system of counting in units the width of the spaces taken up by the pieces of type. The matrices are indefinitely reusable, and the pieces of type, which are used only for the impressions, are returned to the caster. The contemporary Monotype typecaster is controlled by a ribbon of paper perforated on a separate keyboard. It can produce 10,000 to 12,000 pieces of type per hour.

In 1911 the American Washington I. Ludlow perfected a typecasting machine for the large display type that bears his name. The matrices are assembled by hand in a composing stick, which is then inserted above the opening of a mold; the matrices are also distributed by hand.

Reproduction of illustrations

The first process for reproducing illustrations was xylography, using woodcuts that printed in relief and that therefore could be combined with letterpress, the picture blocks and the pieces of type for texts being locked into the same form. As early as the second half of the 15th century, xylography faced competition from engraving on metal that printed by intaglio; the metal plate (copper, sometimes brass, zinc, and even steel after 1806), engraved with a tool (burin) or etched with acid, was inked and carefully wiped so that ink remained only in the incisions and was transferred to paper under pressure in a cylinder press derived from the rolling mill. Since the intaglio method of printing was not compatible with woodcut printing, sheets of text and of illustrations for the same book had to be printed separately.

Presses for printing curved intaglio-engraved plates were perfected during the 19th century with mechanized inking with the use of rollers and wiping with the use of revolving cloth bands or rotating disks covered with calico. Their printing capacity was limited.

As early as the end of the 18th century, however, intaglio printing had inspired a method for continuous printing of textiles by passing them under an engraved and inked cylinder from which excess ink had been removed by a scraper. In France in 1860 this technique was applied to printing paper for school-book covers. A solid copper cylinder was engraved not with continuous lines but with a multiplicity of tiny cavities in such a way that they retained the ink uniformly despite gravity, centrifugal force, and the action of the scraper. The process was suitable only for simple graphics.

Lithography: Senefelder (1796)

A third printing process that had undergone significant development was lithography, neither relief nor intaglio printing but based on the principle that water and grease will not mix. In 1796 Aloys Senefelder of Prague investigated the properties of a stone with a calcium carbonate base and a fine, homogeneous, porous surface. A design drawn on its surface with greasy ink, wetted with water and then brushed with ordinary ink, retained the ink only on the design. This could consequently be reproduced on a sheet of paper pressed against the stone. Senefelder also established that a design drawn on such a stone and printed on paper could be transferred to another stone in as many identical copies as desired, side by side, which made it possible to obtain several copies at a time by printing a single large sheet. He further established that a metal such as zinc had the same properties.

Senefelder envisaged a press in which the stone, secured to an undercarriage, was inked, covered with the sheet of paper with a sheet of pasteboard above it, and submitted to pressure. By 1850 the first mechanized lithographic press with a cylinder, flannel-covered rollers for wetting, and rollers for inking was perfected.

The fact that it was possible to replace the stone by a zinc plate that could be curved made it possible to build rotary presses (the first in 1868) in which the paper passed between the plate-bearing cylinder and the impression cylinder.

Photosensitivity: Niepce (1820s)

While searching for a means of automatically inscribing an image on a lithographic stone, then on a tin plate, in order to engrave it in intaglio, Joseph-Nicephore Niepce in the 1820s established that certain chemical compounds are sensitive to light. This marked the origins of photogravure and led to both the invention of photography (between 1829 and 1838) and the use of photographic processes for the printed reproduction of photographs.

In 1852 William Henry Fox Talbot, a British scientist and inventor, placed a piece of black cloth (tulle) between the object he wanted to reproduce (the leaf of a tree) and the photosensitive coating spread on a steel plate and obtained a picture that retained the fine mesh of the tulle. Consequently, etching with acid resulted not in an extensive and uniform erosion of an area but in tiny juxtaposed pits all over the photosensitive coating and varying in depth according to the degree of exposure. Talbot simultaneously had invented the screen and also had opened the way for a new development in intaglio printing: rotogravure.

The screen was perfected in the 1880s by substituting for the cloth two sheets of glass with uniform parallel lines that crossed perpendicularly. The screen made possible letterpress and lithographic reproduction of the full range of tones of a photographic document by using the effect of the diffusion of light through the mesh of its grid and converting the different intensity of tones into the different thicknesses of the printing surface.

Gravure and rotogravure (1890s)

The circular mechanization of intaglio engraving, meanwhile, came up against two associated difficulties: the need to engrave an infinite number of tiny cells and the need to engrave them directly onto a cylinder. There were problems, because the rubbing of the squeegee to remove excess ink excluded the use of a curved plate that would not have provided a uniform surface in the area in which it was attached, and it was not possible to get photosensitive solutions to adhere to a cylinder.

In 1862–64 J.W. Swan of Britain invented carbon tissue, paper coated with gelatin that can be rendered photosensitive and exposed to light before being applied to a metal surface of any shape.

In 1878 a Czech, Karl Klič (also spelled Klietsch), thought of copying a grid screen directly onto carbon tissue, which could be used to transfer the cells necessary for intaglio printing to a cylinder at the same time as the image to be reproduced. In 1895 Klič, with English colleagues, founded the Rembrandt Intaglio Printing Company, which published reproductions of pictures, on paper, by rotogravure. They kept their process a secret.

In a parallel way, patents for a slightly different process, in which the image to be reproduced was screened before making the impression on the carbon tissue, were taken out in Germany and the United States. But a workman from the Rembrandt Intaglio Printing Company emigrated to the United States in 1903 and there revealed Klič’s secret, and rotogravure, using his method, became widespread.