This article presents all the information you need to know about die cutting. Read further and learn more about:
Die cutting is a bulk production technique employed to cut materials like paper and chipboard into specific shapes using a die. A die is a custom-crafted tool with sharp edges tailored to the desired two-dimensional shape for the cut-out. This process resembles using a cookie cutter to mold dough. Die cutting is applicable to various materials, encompassing paper, fabrics, rubber, fiberglass, metal sheets, foam, wood, and plastics.
The practice of die cutting emerged during the first industrial revolution, fundamentally altering the shoe manufacturing sector. Prior to its development, shoemakers laboriously hand-cut soles, resulting in limited production. Die cutting introduced templates that streamlined and standardized shoe sole production. Over the years, this method has transformed various industries and continues to advance for more intricate designs.
In the modern era, die cutting has embraced technological progress, leveraging computer-aided design (CAD) fed into CNC machines for both automatic and semi-automatic functions. Widely used in packaging, consumer goods, and automotive component production, it is also applicable to DIY projects and office environments.
Die cutting offers speed and efficiency, with performance hinging on stroke speed, material feeding method, and machine type. Typically, it outpaces waterjet cutting and some blade methods. Despite upfront expenses, the efficiency, rapidity, and high-quality output of die cutting ensure its cost-effectiveness.
This straightforward process is suitable for both low and high-volume manufacturing contexts. In industrial settings, die cutting machines can be positioned downstream, processing material delivered by a previous operation. This adaptability allows the machine to carry out additional tasks like forming, perforating, and scoring using single or multiple strokes on a press.
Industrial die cutting machinery, including flatbed, rotary, and semi-rotary models, caters to thicker, more durable substrates and provides fast output rates. Conversely, manual and digital die cutting devices are ideal for crafting simpler components and accessories, with slower production speeds making them better suited for smaller batch orders.
Die cutting is a straightforward process ideal for both low and high-volume manufacturing. In industrial settings, the die cutting machine can be positioned downstream, processing material that is the output of a preceding process. This versatility allows the machine to perform additional operations such as forming, perforating, and scoring, all through single or multiple strokes on a press.
Industrial die cutting machines, including flatbed, rotary, and semi-rotary models, are designed for thicker, more rigid substrates and offer fast production rates. In contrast, manual and digital die cutting equipment are suited for creating simpler parts and accessories, with slower production rates making them better for low-volume orders.
The stock material is moved from the feed tray or roll to the flatbed using a suctioning, pushing, or pulling system. It is crucial to manage the feed rate and the positioning of the sheet accurately to ensure precise cuts and avoid cutting errors.
The cutting assembly consists of a die board and a lower counter plate. The die board is a rigid, flat upper plate that contains a series of knives for cutting the stock material into the finished parts. It is designed to absorb shocks and resist warping under high pressure, ensuring accurate cuts and preventing material deformation. Customized tools attached to the die board define the shape of the finished part.
The steel rule, or cutting edge, is a metal strip bent to outline the finished part. Pressing the steel rule onto the material can result in full or partial cutting. Full cutting penetrates the entire thickness of the material, affecting all layers.
Partial cutting uses a lower rule blade that is narrower than in full cutting, resulting in only part of the material's thickness being cut. This lower rule may not be as sharp, allowing for folds to be created.
When die cutting thicker materials like foam, the sidewalls of a part may lose accuracy and become concave due to the pressing force. For multiple parts, lamination might be used to achieve the desired thickness.
Punches are added to the upper plate to create internal cut-outs in standard shapes such as circles, ovals, or squares. Self-ejecting punches often have a larger diameter than the holes they create.
Rubber ejection strips are self-adhesive and placed around the rule to help remove the finished part after cutting.
The lower counter plate supports and holds the stock material during the cutting process. The cutting head applies a downward stroke to compress the material, causing the die edges to penetrate it. Different die board configurations are used based on the cutting and punching requirements:
A simple die performs a single cut in one stroke of the press.
A compound die makes multiple cuts or impressions in a single stroke. An example is seen in washer production, where the die cuts the outline and pierces the inner hole simultaneously.
Compound dies combine steel rule components for less detailed shapes with metal components for intricate shapes. They produce a finished blank in one stroke and are designed to remove the slug, enhancing process efficiency.
Compound dies consist of male and female components, with the cavity part on the lower shoe and the cutting component on the upper shoe. Pressing these together produces a completed part.
A progressive die is employed for processes involving multiple cutting and secondary steps to produce a finished product. Each stroke of the press creates a different cut or impression, with the sheet being moved to the next operation between strokes. This method requires precise setup and alignment of the stock material. The part stays within the stock material until it reaches the final station where it is fully separated. As the die performs more operations, the design becomes increasingly complex and optimizing the pressure used becomes more challenging.
A combination die performs various cutting and forming operations, such as extruding and bending, all in a single stroke.
For a precise cut, it's crucial to consider the material properties. Thicker and more rigid materials require thicker dies and higher pressure.
During this step, a single finished part is separated from the excess material and other parts produced in the batch. This can be done manually or with mechanical assistance. The excess material may be reprocessed or recycled.
Rotary die cutting machines operate continuously at lower cutting pressures and constant speeds, making them well-suited for being positioned directly downstream from a previous process. These machines are ideal for producing simpler and lighter parts, offering versatility for various materials and a quicker turnaround than flatbed die cutters.
The stock material, or web, in sheet or roll form, moves through the cutting assembly. This assembly consists of a rotating cylindrical die mounted on a rotary press and an anvil cylinder pressing against the rotary press. As the web passes between these rotating cylinders, it is compressed, allowing the sharp edges of the die to cut through the material.
A rotary die cutting machine can perform both full and partial cutting. While the fundamental steps are similar to those in flatbed cutting machines, the mechanism of the cutting assembly differs.
There are two types of rotary dies, chosen based on the material properties and economic considerations.
Flexible rotary dies are crafted from thin steel sheets with engraved patterns that form the cutting edges, wrapped around a magnetic cylinder. They are suited for low pressure and shallow or partial cuts. The thin cutting sheet can be replaced according to the specific part to be cut, and the magnetic cylinder can accommodate various flexible dies.
These dies are cost-effective and easier to manufacture, with minimal downtime during replacement. However, they are less durable compared to solid dies.
A solid die features engraved, abrasive patterns directly on the rotating cylinder. Designed for higher pressure applications, it can handle deeper cuts on thicker and multi-layered materials due to its ability to exert greater forces. Solid dies can be sharpened when worn out, offering greater durability and flexibility. However, they come with higher initial and maintenance costs.
When operating a rotary die cutting machine, several operating and material conditions must be considered:
This type of die cutting machine is similar to a fully rotary die cutter but utilizes only one cylinder containing the die for cutting. The semi-rotary die cutting equipment is programmed so that the cylinder moves in a single direction while the web moves back and forth. This combination of cylinder and web movement allows for multiple cuts, eliminating the need for an additional cylinder.
Semi-rotary die cutting machines are generally less expensive than fully rotary and flatbed die cutters. However, they are limited to low-pressure applications.
While industrial-scale die cutting machines have been discussed, the following equipment is used for creating simpler parts with a relatively low production rate, making them suitable for small-scale applications:
Manual die cutters operate by pushing a crank lever, which presses the steel dies onto the substrate to cut out the finished part. This method is ideal for soft materials like paper.
Manual die cutting is particularly suitable for producing auxiliary items. This equipment is compact and portable, commonly used in homes, offices, and craft spaces.
A digital die cutter is a versatile machine controlled by computer software or cartridges. Unlike traditional die cutters, it uses sharp blades instead of steel dies and is powered by electricity. Digital die cutting machines, like manual ones, are suitable for indoor installation.
The die can be customized to add specific details and features to the finished part based on the end application. The capabilities of a die cutting machine include:
Through cutting is a die cutting technique where the sharp edge of the die extends through the entire thickness of the material, resulting in complete separation of the part. In multi-layered materials, this means cutting through the face, adhesive, and backing layers. Dies used for through cutting can also be designed to score, crease, and cut in a single stroke. The blade for through cutting is longer and thinner than those used for scoring or creasing, enabling it to cut through any depth or thickness of the material.
Kiss cutting, on the other hand, is a type of cut in which the edge of the die partially cuts through the material‘s thickness and only forms the perimeter of the finished part. For multi-layered materials, only the face and adhesive layer are cut. The part is not fully separated from the stock material but can be easily detached on the kiss cut.
Perforating, also known as piercing or coining, is a die cutting technique that creates a series of small, punched holes arranged in a line across the material. This process uses pressurized force to produce these holes. The spacing between the holes affects how easily the material can be torn along the perforated line. While perforating does not fully separate the part from the stock material, it allows for easy detachment along the perforated line.
In cut scoring, the die creates a partial cut or a small indent along a stress point on the material without cutting through its entire thickness. This technique only slices less than half of the material's depth, facilitating easier tearing. The scoring tool's blade is shorter and thicker compared to a full cut tool.
Creasing involves creating indents aligned along a line by applying pressure to reduce the material's thickness on one or both sides. Unlike cutting or perforating, creasing does not create a pierced perimeter, and the depth is shallower than that of cut scoring. This process helps in making even folds, facilitating the creation of three-dimensional profiles. The resulting folds are more flexible and precise, enhancing the material's ability to form distinct shapes.
Broaching uses dies with a combination of multiple teeth that pierces together on a single stroke to cut extremely thick or rigid material. Other die cutting machine capabilities utilized to decorate the finished part are embossing, engraving, forming, and drawing.
The flash cutting process uses an oscillating knife instead of a die to cut materials at varying depths. This technique allows for a broad range of cuts, including engraving, milling, plotting, kiss cutting, and creasing. The cutting machine holds the blade steady, ensuring accurate and clean cuts. Ideal for rapid prototyping and producing aesthetically perfect parts, flash cutting is a CNC-based process where cutting parameters are programmed into the CNC machine. It eliminates the need for tooling, enabling faster project completion and quicker market readiness.
Steel rule dies are an essential part of the die cutting process. When die cutting was introduced over 150 years ago, dies were made by hand and placed in pieces of wood. The use of wood for die cutting is still quite common today, but the manufacture of dies has progressed with technology and become a more automated and efficient process.
Design: The die design is created using computer-aided design (CAD) software. Accurate dimensions and parameters are meticulously examined to ensure precise proportions.
Foundation: For a steel rule die, the foundation consists of a flat base made of wood or metal. In rotary dies, the foundation is a curved piece of metal or wood that will be mounted on a metal cylinder, or it is itself a metal cylinder.
Laser Cutting:For flatbed die cutting, the design is laser cut into the foundation for the placement of the steel blades. These kerf or precision cuts are the preparation process for the placement of the blades.
Shaping of the Blades: The shaping of the blades is done using programmed CNC machines, which produce the precise shapes of the kerf. Blades can be either complex and intricate or simple and uniform. For cylinder or rotary dies, the die is engraved directly into the surface of the cylinder.
Slotting: The steel rule is securely affixed to the foundation, ensuring a sturdy and stable cutting tool for flatbed dies.
Ejection Rubber: Ejection rubber is added to the die to facilitate the safe removal of the cut piece and to prevent the final cuts from tearing, fraying, or sticking to the steel rule.
Rotary Dies: Dies for rotary die cutting are designed using CAD software, similar to flatbed dies. The shape is cut into the foundation using CNC machining. Unlike flatbed dies, rotary dies are cut or engraved into partial or full cylinders. They can be flexible dies, made from thin sheets of engraved steel on a magnetic cylinder, or solid dies, which are engraved into a solid metal cylinder. Flexible dies are less costly due to their simplicity, whereas solid dies are more durable, longer-lasting, and available in various metals.
The way a part is designed, including its details and material characteristics, affects both the production process and the final product. A poorly designed part can result in processing and handling issues, ultimately causing problems for the user.
Below are four fundamental aspects of designing die-cut parts, along with key guidelines to follow. These guidelines are focused on optimizing the part's reliability throughout its handling and usage.
Blanks refer to the cuts that define the perimeter of the finished component. They play a crucial role in detaching the part from the base material during the stripping phase. To prevent issues, it's important to design the part and die to avoid sharp internal or external corners. These corners can act as stress points, which may lead to tearing or fractures, particularly in thin or delicate materials.
Incorporating rounded internal or external corners helps to reduce the risk of tearing and fractures, thereby enhancing the durability and longevity of the part.
Holes are void areas contained within the boundaries of the part, created using punches or steel rules. To avoid tearing and operational issues, the positioning of holes along the material's plane should be carefully managed:
Incorporating cuts, creases, and perforations into the design facilitates easier folding and tearing for the user. Nevertheless, these features introduce extra stress points in the completed product.
Tabs are incorporated into the design to secure corners and edges, adding a three-dimensional aspect to the stock material. Tabs can be positioned either outside the edge (external tabs) or within the plane (internal tabs).
The die cutting process enables the creation of a diverse range of products, components, and materials. It is a technique known for its precision, quality, and capability for high-volume production. However, selecting the most suitable method can be challenging due to the variety of die cutting techniques available.
Basic Flatbed die cutting is one of the most straightforward types, ideal for general cutting or small production runs. It offers great flexibility, capable of cutting and shaping various materials. This method operates systematically, moving the die up and down with accuracy. Flatbed die cutting is particularly effective for products requiring adhesives, as it allows for easy and quick tool changes, and the costs for tools and dies are relatively low compared to other die cutting methods.
Fast and Quick Rotary die cutting is exceptionally fast, which makes it the most cost effective die cutting technique. Heavy and huge rolls of raw material are fed into the rotating cylinders that rapidly cut the fed material into the desired shapes. Several impressions are cut with each rotation to produce large quantities of high quality products.
In contrast to flash die cutting, both flatbed and rotary die cutting require significant adjustments when design modifications occur. These methods utilize conventional dies that need to be reworked for any design alterations, updates, or enhancements.
Die cutting machines play a crucial role in modern industry by allowing for efficient and accurate fabrication of diverse materials, benefiting sectors like packaging, printing, automotive, and electronics. Below, we explore several leading die cutting machine brands available in the United States and Canada. This includes details on specific models, manufacturers, and the unique capabilities, features, or characteristics of each machine:
Features: The Bobst EXPERTCUT 106 PER is a high-speed die-cutting machine engineered for both precision and efficiency. It boasts advanced automation and electronic control systems to streamline operations. With quick setup and changeover capabilities, it minimizes downtime. The machine's robust build and high cutting force allow it to handle a variety of materials. Additionally, the EXPERTCUT 106 PER includes numerous safety features to ensure operator protection.
Features: The Heidelberg Dymatrix 106 Pro is a highly adaptable die-cutting machine designed for premium finishing. It combines die cutting, embossing, and stripping in one versatile unit. Equipped with state-of-the-art servo technology, it ensures accurate control and alignment. The machine is also equipped with a user-friendly interface and integrated workflow management to boost efficiency. Additionally, the Dymatrix 106 Pro facilitates automatic job transitions and offers remote diagnostics capabilities.
Features: The KAMA ProCut 76 is a compact, adaptable die-cutting machine ideal for small to medium-sized formats. It provides versatility with capabilities for hot foil stamping, embossing, and various finishing tasks. The machine is equipped with an accurate registration system for precise cutting and alignment, and its modular design facilitates seamless integration with additional post-press equipment. Additionally, the ProCut 76 includes a variety of safety features and energy-efficient components.
Features: The Kluge OmniFold 3000 is a versatile folding and gluing system that also integrates die-cutting functions. It delivers high-speed production and efficiently handles a wide range of materials.
The OmniFold 3000 is equipped with adjustable platen pressure to achieve optimal die-cutting results. It features an intuitive touchscreen interface and allows for rapid changeovers. The system also supports seamless integration with other Kluge machinery, providing a comprehensive finishing solution.
Features: The MarquipWardUnited VersaCutter is an adaptable die-cutting machine tailored for the packaging sector. It provides precise cutting, creasing, and embossing capabilities across a range of substrates. The machine’s modular design allows for easy customization and expansion. It also includes advanced control systems for precise registration and consistent job performance.
The VersaCutter comes with built-in safety features and is designed for straightforward operation and maintenance.
Keep in mind that the availability and specifications of specific models may change over time. For the most current information on models that meet your needs, it's recommended to reach out to the manufacturers or their authorized representatives.
Die cutting is the process of cutting a sheet or roll of stock material into a smaller and more useful form using tooling called a die. It dates back to the mid-19th century to modernize the shoemaking industry. This manufacturing process has evolved to meet increasing demand and create more complex designs.
The stages of a die cutting process are feeding, cutting, and stripping, which is common to all die cutting methods.
Flatbed die cutting machines utilize an assembly to cut the stock material through a press. These machines are capable of operating at high pressures, giving a more precise and deeper cut.
The press of a flatbed die cutting machine consists of a die board and a lower plate. The die board contains the cutting and punching tools, and a rubber ejection strip. The lower plate supports the stock material during cutting.
The die board has several configurations depending on the cutting steps involved: simple, compound, progressive and combination dies.
Rotary die cutting machines operate in continuous production mode at a constant speed and lower pressures. It utilizes two cylinders: a cylindrical die and an anvil rotating in opposite directions to cut the moving web.
The two types of rotary dies are flexible die and solid die.
Die cutting machines are also capable of making kiss cuts, scores, and perforated holes, which define the characteristics of the part.
There are part design considerations for the die cutting process to maximize reliability during handling. The four basic elements of die cut parts (blanks, scores, holes, and tabs) are considered.
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