What Is Rotary Die Cutting?

Rotary die cutting is a basic procedure employed for cutting a particular pattern on any flat stock substance. This process amalgamates cutting and rolling die operations is a perfect way. As far as the end results are concerned, it can be said that rotary die cutting is ideal when the volume of produce is bulk and one wants to go in for a die cutting method that proves effectual. In this process, the engraved die is made to roll over any stock matter and as it passes it cuts the material giving out pieces that are in the required pattern. There are two different approaches of this rotary die cutting process, one is kiss cutting and the other is metal to metal cutting.

If one talks of the industrial cutting procedure, then one thing that is quite worth mentioning is that it is very simple and assures desired end results. In it, the rolling die which is the form of a cylinder is positioned in a stationary position at the rear side of machine used to perform die cutting usually known referred to as the rotary press. Then the stock matter is made to enter into the carved die either using a conveyor belt or any other system which primarily allows it to move along with the material at the same pace. When the stock material is going to reach the desired point, the imprinted die would automatically press down and the end result would be the cut material.

The force of the rolling die plays a vital role in this rotary die cutting process. The rolling die pressure when united with the edges of the imprinted stock material makes it easy for the machine used to perform the rotary die cutting to operate. If the pressure remains same, it would not be a tough thing to obtain same kind of metal to metal cuts. When the cutting is done, comes the turn of the reassembly. The aptly severed tock material substance is made to form the ready to assemble pieces. One would find usage of this type of die cutting in many areas, such as mass production of the flat pieces of the substance and even in the cardboard packaging. When one talks of the cardboard packaging, one important utility that is not to be missed is the packaging tape.

Precisely speaking, there are only a few instances when one might need to cut a particular part of the stocking material, but this is also an integral part of the rotary die cutting procedure. This rotary die cutting process is most commonly going to be used in areas such as postage stamps , mailing labels, and of course the adhesive backing. Some of the common substances that are usually cut following this rotary die cutting process are rubber, metal, paper, vinyl and many other materials that are to be required in a particular shape and size at the end.

The end products of this rotary die cutting process that we all use in our daily lives are cartons, envelopes, labels and documents.

Using Die Cut Techniques

Die cut products will have been through a die cutting manufacturing process and this process allows large or small quantities of the same item to be made into exactly the same shape. Items that are commonly die cut are wood, cardboard, paper, metal, leather and other fabrics.

Many different industries use die cut techniques for a wide range of applications. Lots of companies will produce blank die cut products that are then sold on for people to use as they wish. These are usually designed and printed onto to use for various different purposes. 

Die cutting is commonly used for advertising and promotional purposes and is ideal for creating packaging, point of sale, displays and holders in plastic and cardboard forms. The die cut process is a technique that has been used for years and years and is still one of the best techniques for accuracy and precision that is used all over the world today. 

Lots of items that are made using die cutting techniques will comprise of several die cut components that all are assembled together at the end of the die cut process to create a finished item, whether this is packaging or point of sale items. 

Specialised die cut machines are available and these make die cutting simple, effective and provide wonderful results. The die cut machine will have sharp blades that perform the cutting of the materials and these can be bent into a desired shape to create the results you need. 

Whatever material is being die cut must be placed on flat surface with a supportive backing and the die is then pressed on to the material to cut it. Some die cutting blades are designed to cut through single sheets where as others will cut through multiple sheets at once to provide a number of exact replicas. Each blank will be exactly the same and this is the reason that people use die cutting techniques as the results are perfect every time. 

Companies that provide die cut services may also offer a full in house art work and finishing service to complete your deigns and create any items you may need such as packaging, point of sale and other display items.

Different Dies For Die Cutters

One major advantage of using die cutters is their versatility. Since the output is dependent on the shape and configuration of an interchangeable die, users can perform many different operations using the same cutting machine by simply changing the die. The die in the die cutters can also be specialized for specific projects like those that involve bending, coining, or curling. For the most part the name of the die signifies its specialized purpose.

Bending

Bending is a process where the die is used to deform the material through pressure. An example of this would be bending the L into an L bracket.

Curling

Curling is the process of using a die to roll or bend the material into a curved shape. This is commonly used with door hinges and removing sharp edges on sheet metal parts.

Forming

This is commonly used to form rounded cylindrical parts using a die cutter.

Blanking

Blanking is a method for cutting material by trimming it from its flat exterior edge. The blanking die applies pressure uniformly, creating a precise flat cut.

Coining

This is a stamping process that is used to stamp circular holes in a material. Using a pressurized force clamping a punch and a die you can create intricate and precise products.

Roll Forming

This process is uses a series of rolls to stamp a continuous stream of stock as it is pushed through the die cutters. This is great for long materials that need a specific design.

Broaching

Broaching Dies can be useful when you are shaping a material that is too thick or hard to be cut by other means. This method uses a number of rows of increasingly large cutting teeth to slice away material precisely and with haste.

Drawing

This is process stretches a material to a certain length. You will find this used in products like wires, tubing or bars.

Swaging

This method is used to create a necking down effect on a material using either a cold or hot process. You can see this often in the tapered end of a bullet casing.

Extrusion

Extrusion is similar to coining, with the exception of the material not taking on the impression of the punch as well.

Cut Off

When you need excess material removed from an end product you will use this process. Die cutters using a cut off die will be able to cut or shorten a material to a set length.

Bulging

The bulging fluid die uses water or oil to expand a material. This process is commonly used to expand pipes or other cylindrical parts.

These are just a few examples of the dies used in Die Cutters and the processes they are involved in. The advantage of using die cutters in an industry is largely due to the versatility of the machine. If you have need of more than one of the mention processes then a die cutter is perfect for you. Just by swapping out the die in the machine you can alter the function.

Die Cutters Explained

Die cutters are a fantastic tool that proves to be complex in their simplicity. Die cutting is pretty basic; it involves pressing a sharp edged die blade through or against a material. this part is simple, but when you add in difference sizes and the die blades use, you will start to see the versatility that comes with its simplicity. We are going to go into a little more depth on die cutters and cover the basics.

Density

Knowing the density of the material you are cutting is very important. Sharp edged cutting dies are recommended for soft to semi-rigid materials because the cleanest cut is made after the material has been compressed to its thinnest possible thickness. With materials like paper or cardboard you will want to avoid cutting all the way through it. A 90% cut is all you need because the material will naturally burst apart. This same thing happens among dense plastics.

Thickness

The thickness of the material you are cutting can have a large impact on the type of machine you need. If you are cutting thin materials then you will need to get a piece of equipment that has a cavity to allow the some give. The setup of the machine you are using is heavily reliant on the materials that you are using.

Cutting Multiple Layers
Die Cutters can cut through many layers of a material if it is thin enough, but if you are creasing cartons or corrugated boxes you want to do it one layer at a time. Things like cigarette cartons boxes are ideal for cutting multiple at once.

Effects of Heat

Heating can play an extremely important role when it comes to cutting materials. Some materials need to be heated to achieve the right cut where others need to be frozen.

Types of Die

Die cutters can perform many different tasks. One of the largest impacting factors to this process is the type of die blade that you use. Examples of some die blades are bending, curling, blanking, coining, broaching, bulging, drawing, or swaging die blades. Each of these are used to fill a specific need and they all vary from each other. Chances are if you have a need for your production line, a die cutter can fill it.

Die cutters are fantastically versatile machines that can be quite simple. However the vast amount of modifications that they can be subjected to allows for the do vary tasks from something as simple as stamping out cereal boxes to cutting the metal for door hinges and then curl the end that holds the peg. They can bend metal, cut paper, stretch wires, and even creating tubes. They are highly efficient and recommended for any production line. They require very little maintenance beyond the routine and changing out dies as you move to a different product.

Die Maintenance Service With Quality & Commitment

Manufacturing dies need skilled, talented and experiences professionals facilitate with equipment and tools. Best machineries help in designing and cutting accurate die with perfect alignment. In daily routine, falls, bad storage, rough usage and ill maintenance are quite normal curriculums followed by the users. These products are used for preparing food items that need tremendous hard work. Thus, neglecting the proper storage and handling during the food item production becomes quite justified. For a company involved in manufacturing various types of macaronis, need well designed, robust architecture and durable dies for the uninterrupted production. 

Die maintenance services for such clients become mandatory, as the disks require regular services to keep dies in proper shape. Purchasing and contacting a die maintenance company serving the industry for century or many decades is always advisable. Manufacturing such disk (die) is an art that requires measuring, and ensuring many dimension systematically to bear the loads or pressures of the food products for the production. 

Missing any of the spheres such as size, length, breadth or even dimension for accuracy and proper alignment will reduce the service life of the disks. Advanced machineries, tools and equipment will help the craftsmen to develop and manufacture outstanding durable die for the clients. In addition, decades old companies have the caliber to design and manufacture die as per the specifications provided by the clients or customers. 

Custom die cutting is one of the most tedious, complex and tough procedures followed by the manufacturing company. Designing as per specification and making sure the production demand that provides load on the custom die demands high professionals caliber. 

Quality, commitment and on-time services are the key features that offer peace of mind to the clients or customers obtain die from the century or decade old companies. Regular services, proper die maintenance, quality check using advanced machines, and seasoned professionals inspection always ensures clients for the better die services from such companies. 

Interestingly, the company delivering die and die maintenance services has engaged in production of pet food. Today, such manufacturers are known as one of the leading pet food suppliers in the industry. Such die maintenance entities called as upcoming pet food manufacturing company in the market. The names are associated with best pet food suppliers increasing the appetite by encouraging hygienic and nutrients food in the pet. Therefore, opt for such die maintenance companies delivering quality with commitments for past one century in the industry.

Die Cutting And Its Different Operations

A die is used in manufacturing industries to cut or shape an existing material. Each die matches a particular product it is deemed to create. It may start from small endeavors to those complex 

pieces for technological industries. In this regard the process known as die cutting had been coined.

Die cutting is done by the so-called tool and die makers. The dies are commonly mounted into a press to form other materials like metal sheets and plastic. The components of a die include the die block, blank and pierce punches, punch and stripper plates, pilot, dowel pin, back gage and the finger stop.

Die cutting operations

The terms associated with die cutting operations were made according to the type of die used. Here are explanations on each type:

Bending. As the term denotes, this operation involves bending dies at a pre-determined angle. One common technique produces the so-called L bracket after a piece of metal is bent at a 90-degree angle. It is used in order to form things such as a corner of a box.

Blanking. This makes use of a blanking die to produce flat pieces of material. With a single operation the desired shape is cut from the die. It results to accuracy, uniform appearance and flatness of the output.

Broaching. This is a die cutting operation where a material is removed through the use of a multiple cutting teeth. Instead of using a shaving method, broaching dies are employed to remove material thickness.

Bulging. Bulging dies are used to expand the closed ends of a tube. It has two types namely: the bulging fluid die making use of water or oil in the expansion process; and the bulging rubber die utilizing rubber pads under pressure to move the wall of a particular material.

There are other die cutting operations like coining, curling, drawing, extruding, forming, horning, piercing, shaving, swaging and trimming. The most common applications for these several die operations are metal spoons, forks and knives, aluminum cans and clothing zipper and buttons. Car products such as car fenders, bumpers, doors, hoods, rods, frames and pistons are also results of the process.