Die cutting process are most commonly used all over the world to design different products. Die cutting is a general process which uses a die to shear webs of low-strength materials. Nowadays, different machines have been designed for die cutting. Die-cutting services can serve manufacturing companies with a broad selection of equipment, providing operating capabilities such as cut, kiss cut, perforating, scoring, or crease cutting.
What is a Die Cutting Process?
Die-cutting is a manufacturing process that employs specialized machines and tools to convert stock material into custom shapes and designs. Whether versatile or customizable, the die- cutting process is ideal for a large variety of materials, including paper.
Die cutting started as a process of cutting leather for the shoe industry in the mid-19th century. It is now sophisticated enough to cut through just one layer of a laminate, so it is now used on labels, postage stamps, and other stickers; this type of die cutting is known as kiss cutting.
Die cutting can be done on either flatbed or rotary presses. Rotary die cutting is often done in-line with printing. The primary difference between rotary die cutting and flatbed die cutting is that the flatbed is not as fast but the tools are cheaper. This process lends itself to smaller production runs where it is not as easy to absorb the added cost of a rotary die.
What is a Die Cutting Machine?
Die cutting is using a machine that applies pressure to cut out delicate shapes from paper, card fabric and other materials. By die cutting you can achieve amazing intricate cut out pieces that you wouldn’t usually be able to create with scissors or craft knives.
Types of Die Cutting
Various die-cutting services are available, including rotary die cutting, steel rule die cutting, and digital cutting.
- Rotary die Cutting: It is suitable for applications that require high accuracy design, high precision, and high-volume production runs. It uses cylindrical dies affixed to a rotary press to cut flexible material.
- Steel Rule Die-cutting: The steel rule die-cutting needs a flatbed fie-cutting press, and custom steel rule dies to convert the material into custom designs and shapes. The process is ideal for thicker material, producing more significant parts, or short production runs. Lastly, digital die cutting converts material without the use of dies but uses blades or other precision tools to produce the desired design, scores, and parts. Based on the type of die-cutting process needed, it will employ a variety of die-cutting machines and dies to produce the cuts, and design, to your specifications and needs. For example, a flatbed die-cutting process requires a flatbed die-cutting press and steel rule dies.
- Lase Die Cutting Machine: Laser types of die cutting machines are more modern and the go-to choose for projects that require the unique combination of speed and accuracy. Laser die cutting equipment applies a fully-focused, non-thermal ray to seamlessly die cut nonmetallic elastomers into a virtually endless array of components or industrial gaskets of any shape or size. Unlike other types of “die” cutting, the laser process doesn’t use a physical die.
- Rotary Die Cutting: These presses are available in electrical, hydraulic, and mechanical models. Separately, the rotary die cutting process utilizes a rotary die press and custom cylindrical dies. Based on the material being cut, desired lead times, and specification, the rotary die press can employ both solid and flexible cylindrical rotary dies. This method is also used to design PCM of your vehicle.
- Kiss Cutting: For adhesive lined materials, kiss cutting cuts the custom design through the face and adhesive layers, but not the backing material layer. The die cut design is not fully separated from the stock material, but can be easily removed from the intact backing layer.
Die Cutting Machines Specifications
There are several specifications for die cutting machines and die cutters you should consider, including
- Maximum sheet length or working length
- Full sheet width or working depth
- Capacity or operating force
- Open height
Moreover, to determine the die cut tolerance, as a manufacturer, you should consider the following factors:
- Part design and size
- The material being cut
- Production technique
- Tool type (steel rule needed, die board or rule height)
- The skills of the die maker
- Application environment
Die Cut Paperboard Air Filter Frames
Suppose you need air filter frames to suit your HVAC system. Thanks to the die-cutting process, you can now find any size die-cut filter frames or any odd-ball size standard-size frames.
Regardless of what complex die cuts you may need, the companies who develop air filter frames can now produce nearly any design you need.
Paperboard air filter frames get their recognition for having a stable design, optimized filter clamping device, and tight construction. Moreover, they are built-up bank systems for installing
AC and cleanroom applications in manufacturing, industrial, commercial, and medical facilities. Custom air filter frames ensure safe usage, easy replacement, and easy installation, thanks to the die-cutting process.
The die-cutting machine will cut shapes into the paper using a die-cutter system. The die cutter will then place weights on a die and pushes it down onto the material, perfectly cutting it. Die cutting can serve a broad range of industries and companies with a wide selection of equipment, perfectly meeting all needs for all intents and purposes.