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The Ins and Outs of Die-Cutting: What You Need to Know

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Widely used in the printing and packaging industry, the die-cutting process is a versatile way of converting materials into the desired shape and size with the help of specialized machines and tools. It can be used on various materials, like plastic, composite, metal, wood, etc. What makes this process an absolute favorite of many is the precision and customization it offers.

You can come across various die-cutting processes, each with advantages and disadvantages. Flatbed die-cutting, digital die-cutting, and rotary die-cutting are the most common die-cutting processes you will ever come across. It is the specific requirement of each project that determines using a particular die-making process. Now that you’ve got a brief idea of what die-cutting or die-making is all about, it’s time to dive deeper into the subject.

Types of Die-Cutting Machines

For the uninitiated, a die is a metal object with sharp areas for cutting the raw materials into the desired shape and size. They are used in various die-cutting machines, depending on precise requirements.

You will mostly find either manual or digital die-cutting machines. Manual die-cutting machines may or may not have motors to apply pressure for precise cutting of the stock materials. Manual die-cutting machines usually use a crank to cut any given material. The metal die goes through the manual die-cutting machine’s rollers, and the generated pressure is used to give the desired shape to the material.

Today, you will mostly find digital die-cutting machines in sophisticated setups. These machines are controlled by software that is used to choose the desired shape of the end product. The digital die-cutting machines contain an in-built blade that seamlessly cuts the materials into the required shape and size.

Commonly Used Die-Cutting Tools & Services

Flatbed, rotary, and digital are the commonly used die-cutting services. Let’s understand each of these for a better understanding.

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  • Flatbed Die Cutting

    It is a fabrication process most suited for processing thicker materials, completing small orders, producing larger parts, or short production runs. In this process, custom steel rule dies, and a flatbed die-cutting press are together used to cut and get the precise custom shape and design.

  • Rotary Die Cutting

    If you want the highest precision with the most accurate designs, choose rotary die cutting. This fabrication process uses cylindrical dies that are affixed to a rotary press to shape any given material. Rotary die-cutting is usually ideal for high-volume production runs.

  • Digital Die-Cutting

    Want materials cut with high precision? Use digital die-cutting. Computer-controlled lasers, tool bits, and blades are used in the digital die-cutting process to get clean cuts, scores, and creases.

All these three die-cutting processes are widely used, depending on the project’s requirements.

Material Considerations for Die-Cutting Processes

You can process a large variety of materials using die-cutting machines. Wood, plastic, metal, composite, paper, fabric, and foam are some of the materials that can be processed using any die-cutting machine. The material type and properties largely determine the die-cutting process for a smooth application.

A flatbed die-cutting process is ideal for cutting through both soft and hard materials. Flatbed presses are known to exert maximum pressure when compared to other available methods. They can convert any material into sheet and roll form. Whatever material you choose for this process, the die’s geometry and design will always be influenced by the material’s compressibility and thickness.

The suitability of using flatbed die-cutting over others is also determined by the material, so make sure to pay minute attention to the material properties before choosing any die-cutting process.

Coming to the rotary die-cutting process, they are usually used for converting web materials.

Digital die cutting, on the other hand, can be used for converting a variety of materials, like- plastic, paper, textiles, etc.

Alternative to Die-Cutting Processes

Though the die-cutting process has its advantages, it cannot be used for every manufacturing application. You should always be aware of other cost-effective and useful cutting alternatives.

If you’re looking for some direct alternatives to die-cutting processes, it has to be waterjet cutting, mechanical cutting, and laser cutting. Plasma arc cutting can also be considered a viable alternative.

Die-cutting is a versatile process that precisely cuts and converts various materials into the required shape. Its precision makes retail packaging one of the best we can get. Not that you’ve got a decent idea about die-cutting processes, but you can start exploring more about it on an advanced level.

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