All About Rotary Die Cutting Services

Die Cutting is an extremely versatile way of creating, cutting, shaping and forming products made from sheet or roll plastic products. Rotary die cutting is fast and consistent, allowing the production of high volume. There are many different cutting methods, including flatbed, matched metal and rotary. 

What is Rotary Die Cutting?

Rotary die cutting is a process that feeds a roll of material through a die station-containing press. There’s a rotating cylinder blade at this die station that cuts the material. The die rotates through the press in conjunction with the velocity of the material feed to ensure that the blades always make the exact cuts in length. 

Rotary die cutting is done using a rotating cylinder blade and a process that begins with unrolling and feeding the material to two rollers by a rotary press.

Rotary Die Cutting Benefits

Custom rotary die cutting provides an unparalleled level of uniformity producing an extremely unique end product. Speed is also a rotary die cutting advantage. These machines can run hundreds of feet of material per minute, while rotary die cutting offers significant efficiencies in production. Some of Die cutting’s direct benefits include:

  • Cutting products from a web (continuous roll)
  • Producing less waste than other, comparable methods
  • Low-tolerance, precision cutting
  • Fast turnaround times
  • High volume projects of consistent cut
  • Smaller sized products
  • Multiple process projects

The cost of rotary die cutting is often less than the other forms of cutting. One of the reasons for this is that other methods of production may require multiple operations while rotary die cutting can perform all operations in line, saving time and money.

Presses Used in Rotary Die Cutting

Rotary die presses enable consistent precision and high-speed conversion of different flexible materials. To die cut and kiss cut while laminating, scoring and sheeting in line, rotary die presses can be set up. The rotary dies press web width can determine the width of the material being used, the roll size and how many processes can be designed into the manufacturing process. Both the manufacturing process and the parts cutting rotating die involve detailed preparation and engineering.

Materials Used in Rotary Die Cutting

International Cutting Die, Inc. can process a variety of materials for a wide range of applications using rotary die-cutting services. Materials include felt, fabrics, fiber, paper, metals and alloys, plastics, rubber, foams, composites, and electrical insulating materials.

Services

International Cutting Die, Inc. offers typical services including die cutting stations, die maintenance, die rebuilding, product evaluation and reverse engineering. We specialize in designing and manufacturing top-quality rotary dies to help your business run as efficiently as possible. Our experienced and knowledgeable staff can assist with concepts, manufacturing costs, manufacturing techniques and material considerations. 

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With our rotary die cutting capabilities, we can create parts that match the exact design specifications of products used in a wide range of industries with our rotary die cutting capabilities. With minimal operator interaction and downtime, multiple different materials can be included in your designs at various stages of production. This keeps production times short in order to help keep your project on track.

Call us today at 708-343-3333 or email to info@icd-inc.com so we can discuss your die cutting options. 

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Flatbed Die Cutting or Rotary Die Cutting

When you’re preparing for a product launch, you might not have time to worry about how to create enough die cut in a quick and accurate fashion. So this is where the tools and know-how of precision die cutters come in.

Die Cutting is one of the ideal processes when cutting, forming, and shaping materials because it does not only ensure high accuracy, but it can deliver cut shapes quickly.

A Die Cutting Machine usually uses a small blade to cut out elements from card stock or other common materials such as letters, numbers, and even customize designs. 

There are tons of processes when cutting dies that you can choose but when you need a series of pieces cut from flexible materials like pads, gaskets, or spacers, two of the common techniques are Flatbed Die Cutting and Rotary Die Cutting best since they both are very similar and very different.

Both Flatbed and Rotary Die Cutting processes can produce great end products, but the question is, which one is best for your design and perfectly suits your needs? The following explains the differences between flatbed and rotary die cutting.

Flatbed Die Cutting VS. Rotary Die Cutting

  • Flatbed Die Cutting

Flatbed Die Cutting Machine uses a fixed base that is flat and a movable head. Usually, the Cutting Die is made of sharp metal strips called the Steel Rule, bent in a way that matches the profile of the part to be produced.

When Flatbed Die Cutter shapes the object, the machine stamps out each product using a hydraulic press and steel rule dies. The raw material feeds along the base while the press is pushed down vertically to make the cut. The vertical motion let thicker material to be shaped and results in very little curvature of the material.

Flatbed Die Cutting Machine can process substantially thicker web materials, material only comes in a sheet, the order is relatively small, and when looking for a cost-effective option. 

  • Rotary Die Cutting

It’s high speed, high tolerance, and high accuracy. Due to its ability to perform multiple functions in the same processing cycle, Rotary Die Cutting can produce extremely complicated multi-layer parts. The machine will pull in web materials and may cut the material, laminate, organize, and more. Web materials go in, and finished parts come out.

When Rotary Die Cutter shapes products, the raw material is fed between two rolling cylinders at a very high speed. The shape’s cut out on the rolling die with high tolerance and accuracy and produces less waste than Flatbed Die Cutting.

Rotary Die Cutting Machine is used when the product is thin, the order quantity is large, order needs to be Kiss Cut (Kiss cutting – cutting through the part down to, but not through, the release liner and the parts would be supplied on a roll or pad for easy “peel and stick” application), and design as tight tolerances.

So which should you use? Choosing between the two processes can be an easy decision. Just consider a few aspects: The width of the product: thick or thin?, Is the order quantity large or small?, Does the product needs to be kiss cut?, and Are tight tolerances or product costs important?

Choosing between the two Die Cutting processes are best left to professionals in the field. Contact International Cutting Die (ICD) today, and our experienced team of engineers is available to weigh your options and help you choose.

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What You Need to Know About Cutting Die Design

Great dies start at the design!

Die cutting manually or electronically? Whichever process you take, you need dies to feed though. But right before we get to learn more about Cutting Die Design, it is best to first define what Die is.

Is die cutting something new to you or is it something familiar? Are you someone who may need more clarification about what this is and what cutting die designs are? 

Die cutting is actually a broad term and to fully comprehend what it is, what its designs are, and how this works, it would be best for us to narrow down the scope to understanding what Die means. 

What is a Die?

Die is an engraved stamp for impressing designs upon a softer material. Today in manufacturing, dies are used to create all sorts of products from small items like paper clips to complex pieces used in machinery.

The dies in die cutting are metal-shaped objects with a high, sharp area for cutting. The appearance and the effects are similar to cookie-cutters and its shape are the shape reflected on the paper that will be cut out. There are different types of dies; Steel-rule die is one that’s sharp and protected with plastic or foam for safety purposes. It is designed to cut thicker materials or multiple cuts in one go and more durable.

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From circles, squares, to very complicated or detailed lacy ones, Dies also comes in a wide range of sizes and designs.

Cutting die design includes a detailed work order identifying specific materials, machines, and information process such as bolt pattern, scrap, stripping, among others, applicable according to customer specifications.

How Cutting Die Design works?

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Very Simple!

For manual or electronic machines, die is placed on your cutting material e.g paper/card, often taped and pressed between two plates. The whole ‘sandwich’ passes through the die-cutting machine, sequentially cutting out the design.

For computerized machines, die designs are either built into the machine rather than using physical dies. At times, the machine is connected to a computer with a stock of images loaded onto it.

Die cutting is a highly-skilled, meticulous task that requires a great deal of attention to detail and knowledge expertise that is why teaming up with the leader of Die Supply Industry, International Cutting Die (ICD), makes business unstoppable and ready to take on the next level of success.

International Cutting Die (ICD) offers a wide variety of capabilities to meet your most challenging die cutting needs!

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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Die Rebuilding and Remanufacturing Services

The die-cut products today depend on high-volume designs, raw materials, skilled production workers, and some form of rolling platform. A die cutting machine forms the approaching line of blanks into a scored and cut form at the core of the operation, a refined shape that requires another processing station to do the folding. All processing stations mesh nicely, but when the die-cutting heart fails, this entire line grinds stops. 

These are some of the common causes of failures:

  • Cutting Dies Breakage. The machine must be taken out of the service if the die is damaged or broken. Proper service is required and dies fracture must be fully welded and re-tempered.
  • Die lifespan Issues. Die failed repeatedly when the volume of the operation rises and works efficiently for only a short period of time.
  • Wear and Tear. Pressure applied by the anvil parts combines with the number of blanks passing through the die-cutting device to weigh heavily on the die, aligned die elements are knocked out of form and distorted by blank material hardness.
  • Cutting Results are Inconsistent. A worn die with a dull cutting edge produces unpredictable results of kiss-cutting, most of which are substandard. The inner system tears up expensive sheets of paper and countless blanks.

Rebuilding and Remanufacturing of used machines are essential to ensure they get the most use possible out their equipment. The entire machine and components cleaned and stripped bare also, inspected for defects, wear, and shortcomings.

What is Die Rebuilding and Remanufacturing Service?

Die Rebuilding Service is disassembling the existing die cutting machine. This method inspects all the parts while replacing those worn beyond repair. On the other hand, Die Remanufacturing Service is used when Cutting Die Machine involves replacing most of the entire system of the machine for about 80-85%.

When finished rebuilding Die Cutting Machine it is stored to the original OEM manufacturing specifications, and it’s the most economical choice available. And also, the machine is equal to good as new upon remanufacturing with new machine technology which exceeds current OEM Specifications. It’s an inexpensive alternative to purchasing a new machine. 

Rebuilding involves mechanical while remanufacturing involves rebuilding with some additional engineering upgrades, and can take considerable effort and time, months in some cases.

When things go seriously wrong call an expert for rebuilding or remanufacturing service, die-cutting is a unique resource and uses many moving parts and meshing forces that must always have consistent results.

ICD International Cutting Die manufacturer for all machine lines and recondition dies from any supplier. Our typical turnaround time is five business days, ICD extends your dies life, ensures proper functionality, and exceeds OEM specifications.

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

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