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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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Your Guide in Choosing a Die Cutting Machine

Die Cutting is a procedure used in many distinct industries to cut paper with the aid of pressing a die built of knife-area blades into the paper. It is a beneficial tool in designing promotional substances, point of sale and packaging mainly whilst larger quantities required.

What is Die Cutting Machine?

A Die Cutting Machine is a machine that is used to cut materials, such as paper, chipboard, fabric, thin plastic and many more. This machine is the cookie cutters of the arts and crafts world since they punch out shapes from flat materials. It provides uniform shapes with clean edges in a more efficient manner than hand-cut pieces.

Factors to consider when buying die cutting machines:

  • Type of machine (Manual or Automatic) – in case you are working to a budget, manual cutting machines are the way to go. Because of the lack of wires, they are very portable and far easier to apply than the more expensive electronic cutting machines. A manual machine works by feeding the material through the slot where it is then either cut or embossed.
  • Cost – die cutting machines can cost from $50 for a basic manual operated machine up to  $1000 for a top end electronic cutting machine. Typically, the more expensive the machine, the more powerful it is. If you plan on using a machine a lot, it’s essential to find something that fits your desires that is easy to work with.
  • Materials and Versatility – consider the project you will be creating with a die cutting machine and the kinds of materials that will be cut. Heavy duty machines are able to cut a greater variety of materials. If you will be cutting mostly with paper-based materials, it might not make sense to invest in a heavy duty machine.
  • Ease of use (Software and Support) – Even when you have the quality of die cutting machine, it may be frustrating to use the machine if the software has a high learning curve or you can’t get support. Research the software that comes with the machine and sees what kind of tutorials are there. Also, research the company selling die cutting machine. 
  • Size and Portability – size and profitability may be a factor. Do you have a small working area? Are you going to cut large materials that require larger cutting width? When buying a die cutting machine, you must have to consider the weight of the machine. In such a case that you might be planning on traveling with the machine often, then you will have to buy for a small one.

You need to consider the quality of the machine. In most cases, the best thing to do is to go with a well-known brand. As a customer, you should always consider reading the review about the machine before purchasing to make sure that it is well-designed and easy for you to use. 

Choosing the right die cutting machine may be a great way to take your crafting to the next level. When you invest in a high-quality machine, you’ve got many greater options when it comes to decorating your crafts. If you are interested in purchasing a quality die cutting machine, the International Cutting Die will help you compare the most popular models on the market. 

For inquiries call us at 708-343-3333 or email to info@icd-inc.com

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Factors to Consider in Choosing the Right Die Supplier

Selecting the right supplier for your die includes scanning a number of price lists and searching for a quality that fits your standard. Your choice will depend on a variety of factors including value for money, quality, reliability, and service. 

By selecting the right ones, your emerging business will be able to equip itself with the tools needed to deliver a specialized service or align the shelves with great products that create sustainable margins.

Things to consider which will help you find the right kind of supplier:

  1. Expertise and Experience – Before deciding on getting a die cutting supplier, the first thing you should do is to research these things. Experience is a precious tool. The die supplier company you choose must have a considerable amount of field experience. An experienced company will easily be able to cater to your requirements, and even offer customized products and look after the installation. However, you should not just settle with the experience. Adequate knowledge along with a flair for innovation is also very essential. The company needs the latest tools available in the market, and an expert team to handle them.
  2. Products – What products are you looking for? An efficient and competent supplier will offer you a range of commercial products as well as industrial components. Some of a die cutting supplier’s most popular products are threaded rods, circles, disks, spacers, washers, insulators, seals, gaskets, and corrugated containers. Take a look at the portfolio of the company you choose. You will be able to know all about their products by reading the experiences of previous customers.
  3. Price and Performance – Cost-effectiveness also comes into play as an important factor. Die cutting requires accuracy and is a time-consuming and costly affair. Therefore, do not choose a supplier with die cutting whose price range is just too good. You must ensure that the service offered by the supplier does not compromise on the quotient of performance and quality. You need to find products at an economical rate, not only with a good final finish. Look for suppliers who will be offering affordable high-quality products.
  4. CNC Machining and Die Cutting – Computer-helped die cutting machine is a very popular trend these days. Form plastic die cutting to metal die cutting – computer-aided cutting designs are in use almost everywhere. It is a technique that attracts attention as the use of computer technology improves the accuracy of production. In this technique, the rate of productivity faces an upturn as dependence on manual labor decreases.

The most efficient suppliers are those offering products or services that match or exceed your business needs. So when you’re looking for suppliers, it’s best to be sure of your business needs and what you want to accomplish by buying instead of just paying for what suppliers want to sell you.

The type of materials you cut is very important to get your work done when choosing the right company. Every die cutting vendor you contact will have specific core skills. Make sure they have previous experience with your material and the right die cutting equipment to process the substrate most efficiently.

Here at International Cutting Die, Inc. we have a team of skilled professionals and known as the rising above current standards in the die supply industry.  We know if you speak with us about your project our experience, professionalism, and capabilities will convince you that we are that partner. Contact us at 708-343-3333 or email to info@icd-inc.com.

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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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