Your Guide to Cutting Die Reverse Engineering

Consumers requirements and business approaches are ever changing. Reverse engineering plays a crucial role to keep pace with these changes and ensure continued development, especially in the production process. But, what does this process entails? How can it help? Here is your quick guide to cutting die reverse engineering. 

Reverse engineering looks into the physical components and functionality of a thing to create a duplicate or to recreate it. Similarly, this special engineering with your cutting dies involves duplication of existing component and redesigning the same to make new ones to comply with new conditions. 

International Cutting Die (ICD) has state-of-the-art machinery to conduct quality reverse engineering processes that produce quality outputs. Our seasoned engineers are capable not only of duplication, but also of creating or adding new features to the new components. It is advantageous for the introduction of new product specs or requirements. 

What happens during the process?

We make use of your existing components that needs upgrading or recreating as part of your maintenance or change in the business requirements. The key to a successful and quality process is a thorough reproduction. It entails a comprehensive or detailed examination and analysis of your existing tools. Once the examination is satisfactorily done, our engineers and designers will lay out a plan for an accurate duplication of your die and stations. 

Why go for cutting die reverse engineering?

  • Update outdated equipment

The business backdrop is always changing, requiring businesses to adapt to the shifting needs. Reverse engineering is a fast and relatively easier solution to keep up with the transformations in the industrial environment. That is,  it enables you to update or reconstruct your outdated equipment to accommodate business changes. 

  • Discover machine flaws

The reverse engineering process gives you the opportunity to intensively check into your cutting die. It provides an opportunity to examine the flaws and vulnerabilities of the die, which is useful to ensure that the reverse-engineered component is devoid of these faults. This likewise brings your attention to your other cutting dies to check whether they have the same issues. 

  • Cost-effective innovations

One of the biggest advantages of reverse engineering is that it supports inexpensive innovations. The process helps you create innovative machineries without the expensive capitalization needs as you don’t actually have to start from scratch. You can utilize the existing components to create new ones that are specific to your needs. 

Know more about our cutting die services. Reach to us! 

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What is the Importance of Cutting Die Maintenance?

Well-maintained dies are one of the most important aspects of the cutting die industry. It’s essential for dies to have regular maintenance in order to produce good parts without delays — and dies that do not function correctly are unacceptable!

Dies are assembled from parts that must work together and should be designed correctly since safe performance begins with good design. Careless operation and poor maintenance will cause great difficulty in spite of the designer’s best efforts.

What is Die Maintenance?

Die maintenance is sharpening cutting sections because of normal wear, replacing springs before their expected life cycle, periodically cleaning the dies and inspecting them for loose dowels or sections, and resurfacing and lubricating components as necessary.

Most likely, the problem is that the die used in the spring has designed improperly or that the spring deflects far beyond its most effective rate. Also, new dies may have design problems that must be corrected to assure smooth operation.

How to Extend the Life of Your Die?

  • Sharpening. Part defects such as burrs, safety issues, and feeding problems, etc. are results of the cutting sections and punch edges break down over a period of time. Die sections and punch should be sharpened periodically. Use the right grinding wheel that breaks down and does not load up during grinding small metals that are very hard to cut. Wheels that load up and burn during the process results in softening, heat checking or cracking of the die section or punch. Grind the proper cutting shear, so the cutting angles are balanced reduces the necessary cutting force, and helps quiet down the die. Correct cutting shear reduces the shock loading of the die and press prolonging and die life.
  • Shimming. Maintaining the timing of each die station is essential for shimming procedures. Should use fewer thicker shims, an excessive number of thin shims placed under a die section creates a section of spongy die, which may tend to breathe and move more. Also, there must be sufficient clearance for screws, slug drop holes, and dowels. Inspect all pierce holes to ensure that there is no shim interference in the slug drop hole. Avoid crooked shimming of die sections, and avoid overhanging shim on die sections. Remove all burrs from your shims and before mounting, make sure all sections and shims are free of debris.
  • Inspect and Clean. Look for loose fasteners, missing dowels pins, galled die sections, broken springs, know why it’s broken, replace springs if they’re already close to the end of their normal life cycle, inspect wear plates and cam surfaces, regrind and fit as necessary, check for dulled, chipped, or cracked die sections and replace if needed, ensure that all screws are tight, all necessary mating die surfaces must be lubricated, inspect die to ensure that all safety guards are in place, all debris like slugs, slivers, and lubricant buildup from the dies must be cleaned, make sure to dry die so it will not rust and all cutting punches are secure in their retainers.

A regular schedule for die maintenance is very important and necessary activity. Without die maintenance, parts of the machine may fail, and repairs can be more costly and time-consuming.

International Cutting Die (ICD) know the importance of keeping machines and dies maintained and best way to keep it maintained is to contact (ICD), we make sure that we extend the life of your dies, ensures proper functionality, and meets OEM Specifications!

Click here to see more of our services: www.icd-inc.com/services/

Contact us at (708) 343 3333 or email info@icd-inc.com for further queries.

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Why You Should Choose ICD for Cutting Die Rebuilding?

When the majority of business operations relies on machines, a piece of non-performing equipment poses risks of operational disturbance and loss. Most sites with cutting dies cannot afford a broken or ill-functioning station because it can affect other phases of the entire production or process. When having your cutting dies for repair, rebuilding or reconditioning, here are the reasons why International Cutting Die should be your provider.

 

Full Die Rebuilding Service

International Cutting Die has in-house mechanics and engineers trained to provide a spectrum of service to build and rebuild your die cutting machines. Since our founding in 2002, we have helped numerous businesses redesign their cutting die stations. It enabled them to save tons of their investments on equipment as we repurpose their machines into powerful beasts customized to their business needs. Our engineers are also equally capable of reconditioning your cutting dies from any supplier. Depending on your needs and specifications, we upgrade them to tailor-fit any production requirements. It includes disassembling, parts inspection and replacement to reassembling.

 

Quick turnaround

In every business, time is always essential. Short delays can mean a significant loss to the firm. Hence, we practice a quick turnaround time with all our projects. Save from exceptional cases, our normal turnaround time for rebuilding services is five business days. Our experts will exert every possible effort to ensure the least amount of disruption on operations as we work on your machine. You also have the option to have your machinery or its components repaired, built or reconditioned on your site or on our facility. We think of your convenience and satisfaction every step of the way.  

 

Maximized benefits

We provide a triad of vital benefits for you. First, we extend the life of your dies that saves up on maintenance expenses. You make use of your surplus on other important units of the operations. It also cuts down the number of issues to address in the production process. Second, it ensures proper functionality. You should not put up with a weak functioning machine and make-up for it by compromising your human capital or other production aspects. Third, our results and practices meet original equipment manufacturer (OEM) specifications, which assures that we only use the best parts for your machine.

When you want quality and speed, set up a consultation with us and know more of the services we can do for you.

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What is a Customized Rotary Die Cutting Stations and Why You Need it?

What is a rotary die cutting?

Die cutting is a precise and versatile cutting and forming solution to produce forms, shapes, and cuts according to product specifications. Most die cutters can work on different materials from plastics, metal, fabric, and foil. Rotary die cutting (and other die cutting processes) made it a salient part of a business’ product and service production.

 

What is rotary die cutting station?

A rotary cutting die station or machine is one of the basic types of die cutting stations. The machine has a cylindrical die that is attached to the rotary press. The rotary die contains the cutters specifically designed to produce the desired shape or cut on the material. Against it is a cylindrical anvil serving as the flat surface that counters the rotary die’s pressure on the material. In between these two rollers, the material such as cardboard, plastic or metal is fed.

 

Why customize your rotary die station?

 

  • High-volume production

One of the benefits of rotary die cutting is its capacity for high-volume production in contrast to other cutting dies. Customizing your rotary die not only provides you with the required cut or shape for your product, but also ensure that you produce the right amount to suit your inventory and distribution requirements.

 

  • Tailored to product specification

Some businesses have complicated cutting demands or have unique designs that are exclusive to their brand. Customizing your rotary die cutting stations allows you to fit the machine with the demands of exclusive designs, helping you create iconic products. It enhances both its functionality as well as your product identity.

 

  • Reconfiguration instead of purchasing

Die cutting service provider such as the International Cutting Die offers reconfiguration services on existing rotary die machines. Instead of getting a new station, service providers can help you retrofit existing ones. It’ll help you save on equipment investment by your working rotary cutting dies that are already in place.  

 

  • Easier operation mechanism

A customized rotary cutting die further enables you to a simplified operation. In fact, some machines need less human intervention once its program is set. This automated process gives you more opportunity to maximize your manpower, while still ensuring quality outputs from the station.

 

To know more about how customized rotary die stations can help your brand, talk to die cutting station experts for consultation. International Cutting Die is a trusted partner of hundreds of businesses that can provide you guidance on tailor-fitted rotary dies.

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