Die Cutting Machine: Functions, Advantages, and More

Industrial die cutters are widely used in manufacturing, specifically in the packaging process. But these machines have grown more advanced over the years. Today, industries ranging from automobile and medical device manufacturing utilize die cutters in their operations as well.

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For instance, a team from MIT has discovered how to mass produce disposable face shields using die cutting for COVID-19-related use.

One of the biggest advantages of using die cutting machines, therefore, is that they have a wide range of applications. Manufacturers use them for processing cardboard and carton, foam, paper, plastic, rubber, and fabrics, all while ensuring the uniformity of each die-cut piece.

If you’re considering purchasing a die cutting machine, make sure to invest in the right kind. Multiple kinds of die cutters are available today, from manual to digital variations. Each has its benefits and drawbacks that affect your production efficiency.

Types of Die Cutting Machines

Flatbed Die Cutter

A flatbed die cutter uses custom steel rule dies that match the shape and design you want to produce. Hydraulic pressure pushes the die downward to punch out parts from the stock material.

The vertical motion can cause a slight curl on the edges of the finished products. But you can avoid this by determining the ideal thickness or amount of the stock material and learning the right mitigating techniques.

Flatbed die cutters can process materials either in roll or sheet form.

Pros of Flatbed Die Cutting

• Cuts through thicker, denser materials because of its great cutting pressures
• Works on thin materials while ensuring sharp, precise cuts
• Has low tooling and machine costs, making it an affordable option
• Can group parts closely on the sheet, reducing trimmings and scrap materials

Rotary Die Cutter

Rotary die cutters are electrically operated, using rotating cylindrical dies called die stations. You feed the material into the die station, which holds a rotary tool that cuts out the parts from the sheet or roll.

The die stations are available in solid and flexible varieties. The choice depends on the material you’re using, the specifications you’re trying to meet, and the project’s lead time.

Depending on its specs, rotary die cutting machines can perform multiple functions in one processing cycle, including layering and laminating materials.

Pros of Rotary Die Cutting

• Has a quick turn-around time ideal for high-volume production
• Offers a greater level of cutting precision compared to flatbed machines
• Produces zero unproductive motion because of the machine’s constant rotation, unlike flatbed cutters

Digital Die Cutter

Digital die cutters or desktop cutting machines don’t have dies. Instead, they use lasers, blades, and tool bits controlled by computers to execute the designs. You can create designs from scratch using a software then export them to the machine for processing.

This die cutting method is popular among facilities with steep requirements for lead time and volume. You don’t have to create new dies for each project, so you can quickly jump from one task to another.

Pros of Digital Die Cutting

• Digital die cutting software programs are compatible with most machines, making integration easier
• The machines take up less space
• The machines can draw, emboss, and engrave materials, eliminating the need for other machinery
• Can accommodate different kinds of materials, including sheet metal
• Offers the highest level of cutting precision

Die Cutting Machine Functions

The question of which die cutting machine to acquire depends on your operational needs. Die cutters, particularly the more advanced ones, can perform various functions, but not every machine will have all the capabilities at the same time. Consider your production needs to determine which ones you want to prioritize for your die cutting machine.

Below are some of the common functions of die cutters:

Through Cutting

This is the basic capability of die cutters, which is to cut through all the layers and completely separate the design from the stock material.

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Kiss Cutting

Kiss cutting is exclusive to adhesive-lined materials. The machine will cut through the top layers – the face and the adhesive – and leave the backing layer intact. The die-cut part won’t be separated from the stock material, but you easily detach it from the backing layer. Kiss cutting is popularly used for labels and stickers.

Perforating

Perforating means punching in a series of holes onto the design. The design isn’t fully separated from the stock, but the holes make it easily detachable. Some designs include perforations that aren’t intended for easy removal, such as adhesive bandages.

Scoring

Scoring leaves a die indent or partial cut at a single stress point. It only cuts through half of the material, reducing the thickness to allow for profile folds.

Creasing

Similar to scoring, creasing creates a fold line on the stock material. The difference is that creasing produces an inward bulge between two stress points. This indent helps the material hold its shape after you fold it.

How to Make the Most Out of Your Die Cutter

Utilize your die cutting machine to its fullest potential by choosing one that meets your production needs. Consider factors like machine size, ease of use, the materials you normally use, and your volume and speed requirements.

Provide ample training for your staff to make sure they know how to operate, troubleshoot, and maintain the machine. This way, you can avoid downtimes and keep your operations running for maximum productivity.

If you’re still unsure of which die cutting machine to get, SBL Machinery can help you make the right choice. We carry a range of state-of-the-art die cutters and other packaging equipment. Just tell our experts what you’re looking for in a die cutter and we’ll point you to a model that satisfies your requirements.

Die cutting is a broad term that you may have heard your label printer and converter throw around quite a bit, especially if you have uniquely shaped packaging or an intricate logo. While you certainly don’t need to be a die cutting expert – that’s what we’re here for – it helps to understand the basics of die cutting so that you know what you may or may not be able to do. Below, we’ll provide a basic overview of the die cutting process, its meaning, as well as some considerations for designing a label with a custom shape.

What is Die Cutting in Printing?

What is the die cut definition? Die cutting is a fabrication process that uses specialized machines and tools to convert stock material by cutting, forming, and shearing. In printing, die cuts are used to create custom shapes and designs for labels.

It starts with a part called, unsurprisingly, a die. A manufactured die is a specialized piece of metal tooling used to cut a specific shape out of a material. Think of it as a cookie cutter, but instead of a sheet of cookies, it is a sheet of label material. So the die cuts out the label, and excess material (called ‘matrix’) is removed. The ‘die line’ is the outline of where the die will cut, it is usually shown as a thick colored line in proofs.

Die cutting comes in many shapes and forms, some of which are better suited for labels than others. There are three major processes that you should know, so you can figure out what die cut process to use for your custom labels. The three processes that we’ll explore below are flatbed, rotary, and semi-rotary.

Flatbed Die Cutting

Flatbed die cutters use hydraulic presses and other lifting systems to press a die down on a sheet of material. Generally speaking, flatbed die cutting is used for low volume projects and larger sized products. Flatbed die presses tend to be better suited for heavier materials over 1/8” thick like felt, fiber, fabrics, and metals than for most label stocks.

Rotary and Semi-Rotary Die Cutting

Both rotary and semi-rotary use rollers to pass webs, which are long, flexible sheets of material through a machine so that a rolling die attached to a magnetic cylinder makes cuts to the material. However, we find that semi-rotary is better suited for cutting labels because its design makes it more capable of efficiently shearing custom labels.In the semi-rotary process, the cylindrical die rolls in a single direction, but the press moves the web back and forth while cuts are made. This movement allows a printer to use a single cylinder to make multiple cuts in a web. The process reduces the number of times the web needs to be run through a die-cutting system. That means that more complex cuts can be completed faster than in a standard rotary setup and quicker turnaround times for your printed items. After the web is cut, the excess material is pulled away, leaving only your labels behind.

Another important note for rotary and semi-rotary die cutting machines is that they can use either solid or flexible dies. While solid dies are steel cylinders with a design already built into the body of the die, flexible dies are thin sheets of steel that warp around a magnetic cylinder. This makes flexible dies less expensive, which is great for businesses looking for custom dies for their labels.

What to Consider for Die Cut Labels

The die cutting process can vary based on what you need. When it comes to die cutting labels, your design will dictate a lot about the process. For example, we have dies that are regularly available in all your typical shapes, such as circles, squares, etc. However, if you have a custom shape or specific designs elements, you’ll want to make sure that you work with a label converter that knows the ins and outs of die cutting. Let’s start with the shape of your design. While your label design may look awesome, you need to consider whether it will work when printed and cut. Here are some tips to consider for die cut labels:

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• Avoid acute angles and sharp corners. They may tear when the matrix is removed after the die cutting process, resulting in avoidable waste.
• If you want holes within your label, leave enough space between the edge of your label and the hole. Thin strips of material are more likely to tear during removal.
• Add a bleed area that extends your design artwork at least 1/16” past the edges of your label. This helps ensure that there are no accidental white spaces.
• Make sure to correctly add a line of your shape into your Adobe Illustrator file. Mark the die line as a specific spot color and as a joined line on its own layer.

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