Rotary die cutting is a
process that converts a material and changes its shape and design by cutting,
forming, and shearing it. It is a quite versatile process that can customize
the shape of a material. This process is used for handling a wide range of
materials. It finds its applications in many industries, such as manufacturing,
labeling, heat shields, etc.
There are many
types of die-cutting processes like flatbed die, laser, and rotary die-cutting.
The flatbed dies cutting utilizes a flatbed die and press. The laser uses a
high-speed laser cutting machine. The rotary die cutting uses a cylindrical
rotary die and a rotary press. The die-cutting application demands different
requirements and specifications of things such as the materials, sizes,
tolerances, number of materials used, costs, turnaround times, and much more.
Each one of them has its advantages and disadvantages.
The rotary
die-cutting process is smooth and quick. To work on an optimum capacity, it is
important that the rotary cutting machine’s configuration and settings are
optimum. The results also depend on the type of material being cut and its
properties.
Rotary die
cutting has a custom-designed cylindrical die that is attached to the rotary
press. The flexible material can be in the form of roll or sheet. It is put
into the press’s die-cutting area where there is cutting die cylinder and anvil
cylinder, rotating in separate directions. The rotary cutting die can be
flexible or solid. It is the tool that performs the cutting operation. When the
material is fed, the cutting die’s edge compresses the material against the
anvil cylinder and the edge cuts and slits the material.
It is ensured
that the cylinders and web in a rotary die cutting machine, run at the same
speed because it is imperative to have the die cuts properly aligned. Sometimes
the machines also use servo motors to achieve better accuracy and consistency.
Rotary cutting machine
uses many materials such as thin metal, plastic, paper, foam, fabric,
laminates, etc. The type of material and its properties decide the
configuration and settings of the rotary die cutting machine. The property of
the material also impacts the design of the rotary cutting die machine. When
there is a requirement for cutting thicker material, the blade must be greater,
and the angle needs to be steeper. While cutting thinner materials, the blade
height needs to be shallow.
The two main
types of dies are flexible cylindrical rotary dies, and solid cylindrical
rotary dies. Flexible dies use a thin sheet of metal attached to a magnetic
cylinder, and solid dies use engraved solid metal cylinder. Both of these
machines can cut almost all types of materials.