Understanding the Die Cutting Process in Manufacturing - Acme Mills

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Chapter 1: What is Die Cutting?

“Die cutting is the mass fabrication of cut-out shapes by shearing a stock material such as paper and chipboard using tooling called a die. A die is a specialized tool used in manufacturing to cut or shape a material fitted into a press. It has sharp edges used to pierce the material; it contains the custom two-dimensional shape of the finished part. The die cutting process works in the same principle as the cookie cutter where the dough is cut into smaller sizes. Examples of materials which can be die cut are paper, fabric, rubber, fiberglass, metal sheets, and plastic.

“Die cutting started in the mid-19th century to modernize the shoemaking industry. Before die cutting was invented, manual labor was utilized to outline and cut the soles of the shoes by hands. This process required more time and manpower while the rate of production was low. The invention of die cutting resolved these problems in the industry. Patterns were made allowing shoemakers to replicate and standardize the sizes of the soles. Through years of discovery, die cutting had extended to revolutionize other industries and it is still evolving to cater to increasing demand and in making more complex designs. Today, this method is widely used in the manufacturing sector such as packaging, consumer goods, and automotive industries. Applications of die cutting can even be found in our homes and offices.

“Since it is a simple and straightforward process, die cutting is suitable for low or high volume manufacturing. In industrial applications, the machine may be located directly downstream, while the starting material may be the outgoing product from a preceding process. The die cutting machine also has many capabilities, making it a versatile and useful asset. It can perform other operations aside from cutting, such as forming, perforating, and scoring. The process is done on a press through a single or series of strokes.

“Flatbed, rotary, and semi-rotary die cutters are considered industrial-scale die cutting machines, designed for thicker and more rigid substrates able to produce parts at a fast turn around. Meanwhile, manual and digital die cutting equipment are utilized to create simple and accessory parts. Its production rate is relatively slower and therefore suitable for low volume orders.

Chapter 2: Flatbed Die Cutting

“Flatbed die cutting is also known as steel rule die cutting. A flatbed die cutting machine uses a hydraulic press or a mechanical or electrical system to press down the custom-designed steel rule die to the material. This method is suitable for cutting thicker sheets (over 1/8”) as it is capable of exerting high pressures. A variety of materials can be processed using a flatbed die cutter, ranging from soft to semi-rigid materials with varying thickness.

“Flatbed die cutters can operate in batch or semi-batch (wherein products are collected periodically) production and are suitable for processing small production orders and larger parts. This machinery involves the following sub-processes to produce the finished part from the substrate sheet:

Feeding

“The stock material is transferred from the feed tray, or a roll, to the flatbed through a suctioning, pushing, or pulling system. In this section, it is important to control the feed rate and positioning of the sheet to achieve a precise cut and prevent cutting errors.

Cutting

“The cutting assembly is composed of a die board and a lower counter plate. The die board is the flat and rigid upper plate which contains a series of knives used to cut the stock material into finished parts. It is designed to be shock-absorbent and warp-resistant to withstand high pressures, to produce a precise cut, and prevent the material from deformation. Customized tools are attached to the die board to define the form of the finished part.

Steel rule

“The steel rule, or the cutting edge, is a piece of metal bent to form the outline of the finished part. The pressing of the steel rule unto the material may induce full cutting or partial cutting.In full cutting, the cut extends to the entire thickness of the material, extending to all layers. This process causes the part, an enclosed area, or the hole to be separated from its remainder. Partial cutting is done through the use of a lower rule blade. The lower rule blade is slightly narrower than what is used in full cutting so that it only cuts a portion of the material’s thickness. The lower rule may not be sharp to create folds.

Punches

“Punches are inserted on the upper plate to form internal cut-outs which come in standard shapes (circle, oval or square) and sizes. Punches that are the self-ejecting type usually have a larger diameter than the holes they created.

Rubber ejection strip

“These strips are self-adhesive rubber placed around the rule to remove the finished part after cutting.

“To complete the cutting assembly, a lower counter plate is placed wherein the stock material is mounted and supported during the cutting process. The cutting head initiates a downward stroke to apply pressure perpendicular to the plane of the material’s surface. This pressure compresses the material, causing the edges of the die to penetrate against it. The die board comes in different configurations, depending on the cutting and punching steps involved:

Simple Die

“In a single stroke of the press, the simple die performs only one cutting.

Compound Die

“In a single stroke of the press, the compound die creates more than one cut or impression on the web. A typical example of this die type is found in the production of a washer. With this type of die, cutting the outline and piercing of the inner hole is done in a single stroke.

Progressive Die

“A progressive die is used when there are a series of cutting and secondary steps involved to create a finished product. Each stroke creates a different cut or impression, and in between strokes, the sheet is transferred to the next operation. This process requires precise set-up and alignment of the stock material. The part remains in the stock material until it comes to the last station where it is fully separated. The more operation the die performs, the more complex design the die must have; also, the more difficult to optimize the pressure to be used.

Combination Die

“A combination die performs multiple cutting and forming operations (such as extruding and bending) using a single stroke.

“To achieve a good cut, the properties of the material to be processed must be considered. Thicker and more rigid materials must require thicker dies and higher pressure.

Stripping

“In this step, a single finished part is separated from the excess material and other parts produced in the batch, either manually or by mechanical means. The excess material may be reprocessed or recycled.

Chapter 3: Rotary Die and Semi-rotary Die Cutting

“Rotary die cutting machines operate in continuous production mode. It operates at a lower cutting pressure and constant speed, which is ideal to be located directly downstream of a preceding process. Hence, rotary die cutting machines are used to produce simpler and lighter parts. It is suitable for a variety of materials and gives a faster turnaround time than a flatbed die cutter.

“The stock material, or referred to as web, in the form of an individual sheet or roll, passes through the cutting assembly. The cutting assembly is composed of a rotating cylindrical die affixed to a rotary press and an anvil cylinder pressed against the rotary press. The two cylinders are continuously rotating in opposite directions along the horizontal axis. As the web passes through the two cylinders, it is compressed until the sharp edges of the die pierce through the material’s thickness.

“A rotary die cutting machine is also capable of full and partial cutting. However, it is not capable of punching holes. Like flatbed cutting machines, the steps are the same but differ on the mechanism of the cutting assembly.

“There are two types of rotary dies, depending on the properties of the material to be cut and economics.

Flexible Rotary Die

“Flexible rotary dies are made of thin sheets of steel with engraved patterns, which contain the edges for cutting, wrapped around a base magnetic cylinder. These dies are suitable for low pressure and shallow or partial cutting. The cutting thin sheet can be replaced depending on the part to be cut. The magnetic cylinder can be configured for many flexible dies.

“These types of dies are easily manufactured and less expensive. It also requires less downtime during replacement. However, these are less durable than solid dies.

Solid Die

“A solid die has engraved, abrasive patterns on the rotating cylinder itself. This type is intended for higher pressure applications than the flexible die. The solid engravings can exert higher forces that enable the die to create deeper cuts on thicker and multi-layered materials. The solid die can be sharpened once worn-out. This type of die is more durable and flexible. However, it is more costly in terms of initial and maintenance costs.

“When operating a rotary die cutting machine, the following operating and material conditions are considered:

“The tangential speed of the rotating cylinders and the speed of the web must be the same. This ensures proper placement of the material between the two cylinders, resulting in precise and uniform cuts through the entire length.

“The clearance between the rotary press and anvil cylinder must be optimized according to the thickness and compressibility of the stock material. If the clearance is too narrow, higher cutting pressure will be applied which may cause fatigue in the machine components. On the other hand, if the clearance is too large, the cutting pressure is not sufficient to cut the sheet properly. Large clearances are suitable only for partial cutting.

“The rotary die to be selected must have a blade width and angle that is optimal for the material to be processed. Thicker and more rigid materials require a wider and steeper blade.

Semi-rotary Die Cutting

“This type of die cutting machine is almost similar to a fully rotary die cutter, except that it only uses one cylinder, which contains the die, for cutting. The semi-rotary die cutting equipment is programmed such that the cylinder moves in a single direction while the web moves back and forth. The movement of both cylinder and web creates multiple cuts, eliminating the need for another cylinder.

“Semi-rotary die cutting machines are less expensive than fully rotary and flatbed die cutters. However, it is only limited to low-pressure applications.

“So far, industrial-scale die cutting machines have been discussed. The following equipment creates simpler parts with relatively low production rate, hence considered as small-scale:

Manual Die Cutter

“Manual die cutters work by pushing the crank lever which forces the steel dies to the substrate, hence cutting out the finished part. Soft materials like paper are best for this type.

“Manual die cutting is suitable for cutting out auxiliary items. This equipment is small and portable, typically found in homes, offices, and craft tables.

Digital Die Cutter

“A digital die cutter is a versatile cutting machine which is controlled by computer software or cartridges. Unlike the traditional die cutters, it does not have steel dies but is equipped with sharp blades inside the equipment. This equipment is powered by electricity. Like the manual die cutter, digital die cutting machines can be installed indoors.

Chapter 4: Capabilities of a Die Cutting Machine

“The die can be customized to add details and auxiliary purpose to the finished part, depending on the end application. The capabilities of a die cutting machine are:

Through Cutting

“Through cutting is a type of die cut in which the sharp edge of the die extends through the material’s entire thickness, resulting in full separation of the part. For multi-layered materials, the face, adhesive, and backing material layer are cut through.

Kiss Cutting

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“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

“Perforating, or sometimes called piercing or coining, is a type of die cut which leaves a series of small, punched holes placed collinearly in the material by using a pressurized force on the finished part. The spacing of the holes determines the ease of cutting the material. The perforated lines will not result in the separation of the part from the stock material, but it can easily detach along the line.

Cut Scoring

“In cut scoring, the die leaves a partial cut or a small indent at a single stress point aligned collinearly on the material rather than cutting its thickness entirely. The die only cuts less than half of the material’s depth, piercing it to make tearing easy.

Crease Scoring

“Creasing also creates indents aligned collinearly by applying pressure to reduce the material’s thickness on one or both sides of the material. The die does not create a pierced or cut perimeter, and the depth is not extensive as a cut score. The crease score makes even folds to aid in creating a three-dimensional profile out of the material. The folds created from this process are more flexible and precise.

Broaching

“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.

Chapter 5: Design Considerations for Die Cutting Process

“The design of the part and its details, together with its material properties, have an impact on the manufacturing process and the outcome of the finished part. Poor design can lead to losses during processing and handling of the finished part, as well as inconvenience to the end-user.

“The following are the four basic elements of die cut parts and the minimum guidelines when designing. All of these primarily consider maximum reliability during handling and service life.

Blanks

“Blanks are the cuts that form the edges of the finished part. It separates the part from the stock material during the stripping stage. Sharp internal or external corners must be avoided during the part and die design, as this serves as a stress point during stripping and handling. At this stress point tearing and fracture commonly occurs, especially for thin and soft materials.

“Rounded internal or external corners prevents tearing and fracture, resulting in a more durable and long-lasting part.

Holes

“Holes are empty spaces that are enclosed within the perimeter of the part. It can be made by using a punch or by the steel rule itself. However, its placement along the plane is limited to prevent tearing and inconvenience:

“Place the hole at least twice the material thickness from the edge to prevent tearing and bulging during the stripping step and handling process.

“If a series of holes or other similar design features must be made, the clearance between two adjacent holes must be twice the material thickness. If possible, a single oblong hole may be considered to replace the series of holes.

Scores

“Scores in the form of cuts, creases, and perforated scores make folding and tearing convenient for the user. However, it gives additional stress points in the finished part.

“Place a series of holes four times the material thickness away from the score line.

“Avoid placing a hole in the score line. This prevents unwanted tears.

Tabs

“Tabs are included in the part design to attach corners and edges. This attachment gives the stock material its three-dimensional feature. A tab may be located outside the edge (external tab) or enclosed within the plane (internal tab).

“If holes are to be made in the tab, place the hole at least twice the material thickness from the edge.

“Place a hole to terminate the internal ends of the tab. This is to dissipate the stress which causes cracking or tearing during handling. The internal ends should not be terminated with a bare end.

Conclusion:

“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.”

The capabilities of die cutting are vast and include a variety of commercial, industrial and consumer-grade goods. Its versatility makes it suitable for various projects, but die cutting is more effective for some needs than others. Recognizing when to choose this manufacturing method and understanding its limitations will increase the chances of getting the results you want. Discover everything you need to know about this process in our guide to die cutting below.

What Is Die Cutting?

Die cutting cuts pre-determined forms into thin material, such as rubber, foam, plastic, wood, metal and fabric. The process can take several forms. Common die cutting methods include using a laser, implementing a rotary tool or creating a custom die for punching out forms.

The History of Die Cutting

Die cutting has existed for almost 200 years. Not long after the Industrial Revolution, die cutting used a punch to press holes into leather manually. This form of cutting initially helped shoemakers produce shoes more uniformly and at a faster pace by creating precisely cut pieces of leather. Over time, die cutting evolved to become more automated and cut into different types of materials. Today, many industries, from electronics to medical products, take advantage of the customizable forms die cutting can create in large quantities.

Die Cutting Process

The die cutting process depends on the type of equipment used, but it involves choosing the material and selecting the right equipment for the job. For methods that don’t use lasers or a rotary tool for cutting, you may need to create a die.

Methods for Die Cutting

The three main methods for die cutting include steel rule, rotary and laser. Each process has separate pros and cons, and the same die cutting method may not work for every project. The methods for die cutting include:

• Steel rule: Steel rule cutting, also known as flatbed, starts with creating a customized die used for the project. Because the die needs fabrication first, this manufacturing method is ideal for large volume projects that rely heavily on a specific shape.
• Rotary die: Rotary die cutting uses a turning tool to perforate or cut through a sheet of material.
• Laser die: The last kind of die cutting, laser or digital cutting, does not use physical tools or dies to create the forms. A laser can cut more precisely than a physical tool can, so this type of cutting produces parts with high tolerances.

How to Find a Die Cutting Method That Works Best for You

The type of die cutting method that works best for you depends on your project requirements. For mass production, a steel rule cutting with a customized die is best. If you already have dies, you can use this method for whatever project the shape of the die accommodates. For heavier materials, the steel rule cutting method works well because the bed supports the weight of what you’re cutting.

Rotary cutting makes objects like gaskets easily. It can cut materials like fabric, plastic and sheet metal and offers a quick turnaround for high-volume projects.

Laser cutting is a method that professional die cutting businesses use. This type of cutting works best for high-precision work required by electronics and similar industries. Beginners don’t often use this method because of the equipment involved.

What Is Die Cutting Used For?

Die cutting has countless uses. For example, die cutting with a rotary cutter often crafts gaskets out of elastomers or rubbers. Laser cutting can help create electrical insulation to meet the high standards of military equipment. Customized packing inserts made from die-cut foam offer specific forms cut into material to safely cradle the packed products.

What Can You Make With Die Cutting?

As a beginner, you may want to start with paper, fabric or leather die cutting. These materials are easier to cut through. For beginners, crafting projects such as gift cards, holiday decorations, scrapbooking materials, labels and gift tags are ideal places to begin.

What Materials Do You Need for Die Cutting?

For die cutting, the materials used depend on the type of machine you’re working with. For most beginners, a steel rule on a piece of flat material will suffice. Make sure the die will cut through what you want to work with. The amount of pressure used will determine whether the die goes through the piece or creates an imprint, scoring into the material without cutting through it.

A cutting pad under the material can protect the surface underneath, whether it is the die cutting flatbed or another surface.

Where to Find Materials to Use for Die Cutting

Paper, fabrics, leather, wood, metal, plastic and foam are commonly used with die cutting. Find these materials for die cutting and others from hobby stores, craft shops or online.

Materials to Avoid for Die Cutting

When die cutting initially, avoid using extra-thick materials that would require too much pressure from a die. You also cannot use materials too thick to pass through the machine.

Tips for Beginners: Common Die Cutting Mistakes and How to Avoid Them

One of the most common mistakes with die cutting is the die failing to cut all the way through the material. This error can happen if the die does not have enough pressure behind it or if the material is too thick to cut. Try sending the material through the machine a second time or adding a piece of cardstock or bulking material under the project to bring it closer to the die and increase pressure. If these options fail, consider replacing the die — it may have a defect.

The Pros and Cons of Die Cutting

Depending on your experience with die cutting and what you’re trying to achieve, you may find potential pros and cons to the process. Understanding those advantages and disadvantages can help you make the right considerations for your project.

What Are the Advantages of Die Cutting?

Die cutting provides multiple advantages for projects that require it, including:

• Affordability: Die cutting offers an affordable manufacturing option, especially in bulk. Once manufacturers create the needed die, the costs for increasing the order size only depend on the type of material used.
• Customizability: While affordable, die cutting also allows for customizable cuts. Laser and steel rule die cutting can adapt to any shape needed.
• Flexibility: There are many materials this process can cut, including metals and wood. The wide variety of projects that can use die cutting makes it a flexible manufacturing process.

What Are the Disadvantages of Die Cutting?

Die cutting is great for thin materials, but it does not work for all projects. For instance, thick materials or different ones at the same time in the cutter may not work.

Additionally, not using a die cutter properly could result in scoring the material instead of cutting through it. Trying to fix this error by running the project through the machine again could fix it. But if the material shifted between the first and second passes, the second cut may not align with the first, creating a misshapen cutout.

The steel rule dies and rotary cutters are also very sharp. Mishandling of them could result in physical injury. And if you need highly precise cutting, you’ll likely not have access to the laser die cutting machines required.

Professional die cutters with more precise machinery can overcome these disadvantages. Experts know how to control the die cutter’s pressure based on the material to ensure proper cutting. Plus, they can use laser cutting for accurate die-cutting results.

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Don’t risk making a mistake on die cutting projects that require extra skills to achieve. Instead, request professional die cutting to have a quality job done. Die cutting services from a professional company with the right materials and equipment can help you complete your projects.

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