In a die-cutting process, a material is converted into different shapes and sizes, by cutting and shearing it. This process can make various custom shapes and designs of the material. There are many materials that allow rotary die-cutting equipment on them.
Out of the different die cutting processes such as flatbed die, laser die, and rotary die cutting, the rotary die cutting equipment is the most famous and most used. It uses a cylindrical rotary die and a rotary press to perform the cut. The rotary die equipment runs on specific settings to generate the best possible and optimum result.
Rotary die cutting can be done on a variety of materials. The list includes thin metals, plastic, paper, foam, fabric, and laminates. The type of material and its properties decide the configuration and settings of the rotary die cutting equipment and its design too. In rotary die cutting, the gap between the cutting die cylinder and the anvil cylinder creates a cutting pressure. This pressure is exerted on the web. This gap or clearance is then adjusted as per the material thickness and compressibility. If the gap is small, it creates too much pressure and is ideal for heavier die cuts. But if the gap is too wide, the cutting die applies lesser pressure and hence is better for lighter die cuts.
The property of the material also has an impact on the design of the rotary cutting die. The thickness and compressibility of the web determine what should be the ideal cutting blade height and its angle. Like, if you want to cut thick material, the blade height must be kept greater and the angle needs to be steeper. If the material that needs to be slit and shapes is thin, the material needs a lesser height and accordingly, the angle. If the material is multi-layered, it needs to be adjusted at different heights and angles.
Thinner materials like paper can be cut by flexible or solid dies. The thicker and abrasive materials need solid rotary die cutting equipment only.
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