What Is Die Cutting? And What Can Dies Create?
If you’re new to converting or are interested in the details of converting, you’ve probably heard about die-cutting. Die-cutting is a broad term for a fabrication process that creates precise, sometimes intricate cuts from various materials. Die-cutting is a highly efficient process that speeds up manufacturing and minimizes material waste.
All kinds of converters use die-cutting to create simple and complex products. Different types of cutting dies enable manufacturers to reduce downtime and increase production. Let’s dive into this overview of die-cutting and what kinds of products cutting dies can make.
What Is a Cutting Die?
A cutting die is a tool used in converting that fabricates shapes from a piece of material. The cutting die is made of steel or some other metal. Die-cutting is used across manufacturing industries, from automobiles to packaging and labels.
Die-cutting machines come in as many varieties as there are uses for them. These machines can be incredibly complex to handle large-scale manufacturing demands effectively.
However, the key to the entire process is the die itself, the small tool that performs these cuts. The die is a specialized metal piece with the intended design cut or engraved into it. The die-cutting machine presses the die into the substrate with enough force to cut out the right shape. Excess material is then removed. Think of the die as the cookie-cutter that creates perfectly identical shapes from a sheet of material.
Cutting dies can maximize manufacturing efficiency while creating exact, uniform pieces with incredible accuracy. Different types of dies can also perform other actions like:
- Creasing
- Perforating
- Embossing
- Heat sealing
- Punching
- Molding
Types of Cutting Dies
Cutting dies come in a few standard designs, each with its own uses in different manufacturing applications. Knowing the various types of cutting dies can help manufacturers determine which process is best for their specific needs:
Flatbed Cutting Die — High Dies
Flatbed die-cutting is the process of cutting shapes out of a piece of material using a hydraulic press, which presses the die down and lifts it up to complete the cut. These cutting dies are more frequently used in low-volume applications with larger-sized products.
Here are some of the reasons why a manufacturer would choose a flatbed cutting die:
- The material is thick: The construction of a flatbed cutting die enables its use with heavier and thicker materials like fabric, metal, or fiber.
- The material comes in a sheet: Some materials, like sheets of metal or plastic, can’t be fed into a rotary cutting die very easily. It makes more sense to use a flatbed cutting die in these applications.
- The project must be cost-effective: If a manufacturer does not need high-volume output, a flatbed cutting die could be the more cost-effective option. This die-cutting machine is less expensive than most rotary die-cutting machines.
Rotary Cutting Die
A rotary cutting die rotates and presses a design into the material. This material is continuously fed through the die-cutting system in a long, moving stretch called a web. This method is ideal in applications that need high-volume, precision production.
Some of the benefits of using a rotary cutting die include:
- Maximized efficiency: Rotary die-cutting creates shapes on a cycle, reducing the downtime associated with other die-cutting methods. This feature results in a much higher output than traditional flatbed die-cutting.
- Cutting rolled materials: Some materials like cloth, paper, and film come in rolls. These materials can be difficult to manage unless manufacturers can roll them out continuously as they convert the materials.
- Speed: Because the process is continuous, a rotary cutting die can run hundreds of feet of material every minute.
Solid Cutting Die
A solid cutting die is one type of cylindrical die used in rotary die-cutting. This die is a solid steel cylinder with the design permanently engraved into the body. Manufacturers can benefit from a solid cutting die’s features:
- Durability: The solid construction of these cutting dies makes them extremely sturdy and suitable for a range of rugged applications. Solid cutting dies can also be resharpened, further extending their life span.
- Customization: Different kinds of steel enable manufacturers to customize solid cutting dies to their exact specifications.
- Reduction of downtime: Using solid cutting dies can reduce the time needed to change dies during a production run.
Insert Die
If only a single or limited number of cutouts is needed, you may want to use a rotary die insert. This is an individual piece that is screwed onto the main shaft and can be replaced at any time when it wears out. While the benefits of an insert are like those of a solid die, sometimes using an insert is the better choice. This is usually determined by the customer, after consultation with the die manufacturing company.
Insert dies are specially designed to be easily replaced or exchanged in a die-cutting press. Insert dies reduce the need to replace the entire die. There are distinct benefits of choosing insert dies, including:
- Cost savings: Insert dies are often less expensive than traditional solid dies since you can replace just the cutting portion of the die rather than the entire thing. Over time, these savings can add up, especially when you use dies constantly and need to change or update them frequently.
- Time savings: You can quickly and easily change insert dies in a die-cutting press without having to use specialized equipment. This process can help reduce downtime by increasing production efficiency since operators can quickly switch between dies and cutting patterns quickly.
- Customization: Insert dies make it easier to customize the die-cutting process, as you can easily change the shape or size of the cutting portion of the die without having to redesign the entire die. Insert dies are especially useful in industries where products are often customized and updated.
Flexible Cutting Dies and Magnetic Cylinders
Unlike solid dies, flexible cutting dies are thin steel plates with an etched design. These dies wrap around a magnetic cylinder, making them easy to change when needed. Here are a few of the top benefits of using flexible cutting dies in production:
- Affordability: Flexible cutting dies are less expensive to produce than solid cutting dies since they are metal sheets instead of a solid piece If your production run will be shorter, using a flexible cutting die is likely to be less costly than a solid cutting die.
- Versatility: Flexible cutting dies can easily cut through common substrates like paper and labels. These dies are also easy to swap between different types of die-cutting machines.
- Space-saving: Because of their thin construction, flexible cutting dies take up far less space in a manufacturing facility than solid cutting dies.
Magnetic Cylinders
A magnetic cylinder is a must for production with a flexible cutting die. These cylinders are the base to which manufacturers attach the flexible die. (INSERT PICTURE WITH MAG CYL)
- Magnetic die cylinders: Best Cutting Die’s magnetic cylinder is a solid steel cylinder with 100% rare earth magnets arranged around its entirety.
- Magnetic die shells: Instead of having magnets fixed 360 degrees around the cylinder, magnetic die shells are plates of magnets that attach to the cylinder itself.
Two key attributes of Best Cutting Die Cylinders include the following:
- We use rare earth magnets, giving you maximum strength.
- Our magnets are affixed in a circumferential manner, providing this “holding power” at any point around the cylinder and eliminating any “dead spots.”
Using flex dies with Best Cutting Die systems provides several benefits, including:
- Reduced costs: This type of die enables the use of flexible cutting dies, which are less expensive to produce and replace.
- Greater versatility: Magnetic cylinders allow manufacturers to cut a broader range of materials, including paper and films.
- Streamlined operations: A magnetic cutting die allows manufacturers to change flexible cutting dies quickly, increasing efficiency and profitability.
How Are High Dies Made?
The process of manufacturing cutting dies requires high quality and precision. Cutting die manufacturers must take great care to produce cutting dies of uniform thickness that deliver precise, even cuts. Take a look at the steps of manufacturing cutting dies:
1. Hand Forging
To begin the die manufacturing process, workers hand-forge the dies out of steel. Hand-forged steel provides superior strength and gives dies a sharper edge for durable performance. More benefits of hand forging include:
- Better performance: Forged steel dies are longer-lasting and ideal for high-volume production runs, even in harsh environments.
- Uniformity: Hand-forged dies are also uniformly made. With hand-forging, workers can cut dies with more complex, intricate designs. These dies also provide reliable results with minimum variation.
- Reliable strength: Hand-forgings are free from defects or gas pockets that can compromise a die’s structural integrity and lead to breakage. Some hand-forged dies have extra strength due to altering the steel’s grain flow. Die manufacturers through-harden dies up to a 56 on the Rockwell scale.
2. Heat Treating
The next step in the die manufacturing process is heat treatment. This process involves submerging dies in a salt bath at very high temperatures. Because salt can withstand tremendous amounts of heat and has uniform heat transfer characteristics, this method works well to harden steel cutting dies. The salt bath treatment also reduces distortion in the die. This step ensures that each die has a consistent hardness. After the die hardened, it is then tempered in an oven to ensure the overall toughness.
The entire heat treating process performed in-house ensures the best quality. An all-in-house-die manufacturer can complete this step much faster than a manufacturer that must rely on outside sources for heat treatment. With in-house capabilities, the die manufacturer can ensure that the heat treatment process strengthens the die’s integrity and maintains its properties.
3. Tempering
After the die is hardened, workers take it for tempering. Tempering is a heat treatment method that helps improve the properties of the steel used to make cutting dies. This process involves heating the steel to specific temperatures, usually between 302-932 degrees Fahrenheit, and cooling it until it reaches the ideal hardness and toughness. The steel is held at high temperatures for a certain amount of time, then cooled to room temperature.
The steel used to make cutting dies is hardened to improve its resistance to wear and deformation. However, this process makes the steel brittle and susceptible to damage, such as cracking or breaking. This problem is solved by tempering the hardened steel to reduce its brittleness and toughness. The gradual cooling process helps reduce the internal stress of the steel.
Tempering is an essential step in the die-cutting process because it helps extend the life span and durability of cutting dies, which makes them less likely to become damaged or worn down after use. The tempering process helps manufacturers make high-quality dies that can withstand frequent use while providing accurate performance.
4. Chilling
Another process that adds strength to the dies is chilling. State-of-the-art cryogenic chilling chambers can chill hand-forged dies to minus 300 degrees Fahrenheit. Cooling a metal tool at temperatures this low helps relieve stress on the metal, ultimately reducing wear.
5. Quality Control Inspection
Finally, the cutting dies are ready for quality control. This step in the die manufacturing process is crucial because it ensures that each die meets stringent quality standards. The quality control process includes:
- Inspection: The quality control team visually inspects each cutting die, magnifying the die up to 120 times to determine the integrity of the steel.
- Testing: Skilled technicians then test each die using both manual gauges and computer-controlled testing equipment. The technicians look for precise edge quality, concentricity and hardness of the dies. Each die also undergoes simulations of actual production processes to test functionality.
What Industries Make Use of Cutting Dies?
Whether a manufacturer produces clothing, personal care products, or airplane parts, cutting pieces of the right size and design is essential. Cutting dies are used across various manufacturing industries:
1. Nonwoven
The nonwoven industry manufactures fabrics bonded using chemical or mechanical means instead of being woven together. Nonwovens include fabrics like felt, absorbent materials, and plastic film. Because these fabrics are relatively thin and manufacturers need to produce many products, rotary cutting dies are the die of choice for most manufacturers in this industry. Cutting dies are also used to cut and shape fabric and other materials in the textile and garment manufacturing industry.
2. Medical
Many of the products used in the medical industry are also made with nonwoven fabrics, including many wound care products like adhesive bandages, dressings, and pads. Other medical supplies made on a cutting die include surgical gowns, gloves, and medical masks. Cutting dies are also used to produce medical devices such as syringes, catheters, and other medical equipment.
Die-cutting is also used in making medical equipment and pharmaceutical products. Rotary cutting dies efficiently cut pharmaceutical packaging and labels, while other die-cutting technology helps create a range of medical equipment like sterile seals and silicone gaskets.
3. Envelope Converting
The envelope-converting industry needs efficient, reliable technology that speeds up the envelope-manufacturing process while reducing downtime. Cutting dies efficiently produce everything from standard envelopes to custom envelope windows.
Manufacturers in envelope converting may use several types of cutting dies in their processes, depending on their material and the exact specifications. Generally, envelope manufacturers utilize flexible and magnetic cylinders to broaden their production capabilities.
4. Printing and Packaging
Cutting dies are used to produce food and product packaging and various other consumer products. Flexible cutting dies are best for cutting thin materials like delicate plastic films used in the food manufacturing industry. Different manufacturers use rotary cutting dies to create cartons, boxes, and other types of cardboard packaging.
Cutting dies are also used to cut and shape paper, cardboard, and other materials used in the printing and packaging industry.
5. Labels and Direct Mail
Labeling issues cost manufacturers millions of dollars each year. Manufacturers can eliminate costly production shutdowns when labels are cut or printed correctly. Manufacturers in the label and direct mail-cutting industries need reliable tooling and hardworking dies to keep production running. Flexible dies used with magnetic cylinders streamline the process of cutting labels and direct mail.
6. Other Industries
The primary industries for cutting dies are printing, packaging, labels, medical, label converting, and nonwoven industries, but other industries also use cutting dies for various purposes, including:
- Automotive: The automotive industry uses cutting dies to cut and shape various parts and components, such as gaskets, seals, and trim pieces.
- Leatherworking: Cutting dies are used to cut and shape leather in the manufacture of shoes, bags, belts, and other leather products.
- Electronics: The electronics industry uses cutting dies to cut and shape parts such as printed circuit boards (PCBs) and other electronic components.
- Aerospace: The aerospace industry uses cutting dies to cut and shape various parts and components for aircraft and spacecraft.
- Food production: Cutting dies are used to cut and shape food products, such as biscuits, crackers, and pasta.
Overall, cutting dies are an essential tool in many industries, enabling precise and efficient cutting and shaping of a wide range of materials.
What Products Can Cutting Dies Make?
Since die-cutting is used across a broad range of industries, the manufacturing process works with various materials. Cutting dies can cut many specialty and everyday items, including:
- Plastics
- Leather
- Films
- Rubber
- Foam
- Paper products
- Felt and other fabrics
- Metals like steel and aluminum
- Cardboard and other fiberboards
Rotary die cutting can cut virtually any shape into these materials, which makes the process so versatile for use in manufacturing. Some of the most common products cutting dies can create are:
- Food packaging: Die-cutting produces many types of food packaging out of cardboard, paper, and plastic. These packages include cereal boxes, beverage cartons, snack wrappers, and coffee packaging.
- Metal parts: Companies across industries need metal parts fabricated. Cutting dies form and cut these products with superior accuracy and speed. Whether it’s automobile parts, aerospace components, or electronic circuit boards, a cutting die can easily create these essential parts.
- Mailing packaging: Manufacturers also use cutting dies to create a range of mailing packaging like overnight mailer envelopes and flexible packaging.
- Disposables: Cutting dies can also form more detailed disposable items like paper cups, sanitary disposables, fast food containers, and paper towels.
Find the Cutting Dies You Need From Best Cutting Die
At Best Cutting Die, we offer solid rotary, flexible, and magnetic cylinders for every manufacturing application. Our all-in-house process allows us to meet customer requirements and provide the highest quality at every step of the way, from hand-forging to stringent quality inspection. With the flexibility and industry knowledge to meet and exceed customer demands, Best Cutting Die is the one-stop shop for all your cutting die needs.
Besides cutting die production, we offer a design and quote studio where you can design the dies you need for maximum efficiency. Our helpful service team will also assist with after-sale customer service like customer training.
Contact Best Cutting Die today to talk with a specialist or for more information about the world of cutting dies.