Die cutting is a one-of-a-kind fabrication process that adopts dedicated machinery to shape stock material into desired shapes, sizes, and designs.
With the right kind of die cutting equipment supplies, one can work on a wide array of materials like metal, wood, plastic, and even composites.
Owing to its versatility, die cutting finds it uses extensively across a range of industries to manufacture products, like die cutting fabrics, papers, foams, gaskets, and neoprene. Some of the most popular die cutting methods adopted by industries include:
1. Rotary die cutting
2. Flatbed die cutting
3. Digital die cutting
Each process has its fair share of advantages and pertains to special kinds of requirements, depending on the industry they cater to. They largely depend on factors like:
1. Material type???????
2. Size of the parts
3. The desired level of tolerance
4. Costs (Initial and Long term)
5. Lead time
In this post, we take a dig at the die cutting process as a whole, its vagaries, the kind of die cutting equipment supplies that goes into play, the machinery and materials involved, and everything else in between.
Among all other die-cutting equipment supplies that's there, custom-designed dies are the ones that assume a significant role. They are widely responsible for imparting a desired shape and size to a stock material used for a particular industry. A typical due cutting process includes several cutting capabilities, like:
1. Perforation –
This particular method uses punched holes to help secure the intended die-cut design onto the stock material. As the name suggests, one can easily detach the design by pulling it across the perforated lines.
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2. Creasing-
It starts by creating fold lines on the stock material, which in turn, helps reshape any stock material to have an inward bulge resting between two stress points.???????It is the presence of the stress points that distribute the flex across the material and not just at the folding point.
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3. Metal-to-Metal cutting –
Otherwise known as “Through Cutting”, this particular method works by cutting a custom design through the stock material. In the case of plastics that carry adhesive backs, the die-cutting equipment supplies cuts right through the face as well as the adhesive and any backing material that's there. Thus, the die-cut design is readily separated from the stock material without any additional effort.
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4. Scoring–
Taking a drift from other processes, scoring, instead of cutting wholly through the stock material, focuses on a single stress point and either leaves a particular cut or a die impression. Doing so enables one to cut through just half of the material, thereby reducing the stress point thickness for square profile foldings.
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5. Kiss cutting–
Geared towards working with adhesive-backed materials, the method involves custom design cutting right through the face and the adhesive layer, while the backing stays intact. In this case, the die-cut design stays attached to the backing layer and can be removed easily as and when needed.
While there are multiple die-cutting services available, each kind caters to a special type of requirement, has a distinct set of features and limitations, and also varies in output and costs. Let's take a closer look at each type.
Flatbed die cutting –
Named after a flatbed die cutting press that is used, this particular fabrication process is highly suitable for working with thicker materials in large quantities, as well as for short-running production units. Flatbed die presses are widely available as electrical, mechanical, and hydraulic models with system-specific configurations.
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Rotary die cutting-
Cylindrical and flexible dies are the major die-cutting equipment supplies that is used here and are generally fixed to a rotary press. This die-cutting process is meant for working with more flexible materials and any design that demands high precision and accuracy.
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Digital die cutting-
A breakthrough fabrication method that completely does away using physical dies. In place, it uses computer-operated laser beams to help shape up a particular design. Every bit of the design information is passed on digitally to achieve the perforations, scores, creases, and cuts at desired places. The process works well with any low shear material where a fast lead time, low cost, and high precision is in demand.
When it comes to using the right kind of die-cutting equipment supplies, it generally has to do with the kind of material that needs to be converted.
Plastic, wood, paper, metal, foam, fabric, and composites, all can be seamlessly worked on and an optimal die-cutting output can be achieved with proper configuration. However, each die-cutting method works well for a range of materials in different forms, and knowing the same will only help you to boost your production rate.
For instance, flatbed die cutting facilitates working with materials either in roll or sheet forms, whereas rotary die cutting works great with web materials. On the other hand, digital die-cutting assumes a greater efficiency and works seamlessly from any material, ranging from plastic to wood. However, it involves a longer lead time and is a tad bit expensive compared to other traditional die-cutting methods.???????
Die-cutting is an innovative and extremely functional fabrication process that caters to a large number of industries and their manufacturing needs.
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With careful consideration of die-cutting equipment supplies and smart system configuration, one can push the limits of die cutting to greater lengths like nothing else in comparison.
