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Additional Die Cutting Information

Despite the fact that die cutting is limited to applications that shape flat products, the technique is used considerably throughout a wide variety of manufacturing processes. Die cutting tools and machinery can be created to cut items as large as ship components. Some common die cutting products include decorations, automotive and aerospace components, and office supplies.

Die cutting is a common manufacturing process that is used to shape metals, plastics and other materials. One of the most important factors in creating quality die cut materials is the integrity of the die cutting tools.

Die cutting can be compared to a cookie cutter. While the basic process is similar—both use sharp, shaped blades to cut a material—die cutting is naturally more involved. In machining, die cutting serves as a preliminary forming technique prior to finishing and/or decoration. Several die cutting tools may function in a sequence to create a series of cuts that deliver the desired shape.

The Die Cutting Process

In terms of manufacturing, a die is a tool that shapes a material into a desired form. Whereas some dies configure the material through processes such as bending, casting or extruding, die cutting tools consist of one or more sharp cutting blades which cleave the material as wanted. A pressurized-arm presses the die cutting blades down into the workpiece. Some cutting die tools can shape one component at a time, while others cut several layers of material at once.

The Necessity of Forming Quality Die Cutting Tools

The integrity of the die cutting tools is essential to achieving adequate product quality, because an improperly formed tool will result in inferior product shape. To avoid this, using a highly skilled tool and die maker can ensure product consistency. While forming die cutting tools is intricate work and requires considerable lead time prior to production, manufacturers can achieve fast production cycles with minimal maintenance and downtime with these tools.

Beyond shaping accuracy, the consideration of product waste complicates the forming of die cutting tools. A superior die maker will design a die that not only delivers superior product design, but also minimizes waste. To further reduce negative cost effects caused by waste, many die cutting operations also utilize some form of material recycling. This is not only a question of environmental awareness, but also cost minimization.

Types of Die Cutting Tools

Numerous die cutting configurations exist to deliver optimal results for a variety of applications. Some of the most common types of die cutting tools include:

Clicker die cutting: Steel blades are welded with cold rolled steel braces for easy registering of the material. Clicker dies cut tough materials such as Kevlar or fiberglass and glove and shoe manufacturers often employ them.
Rotary die cutting: A cylindrical die cutting tool, rotary die blades can create corrugated boxes, but are also used to cut plastics, foam and rubber. The blades are formed around the outer surface of the cylinder, with blades ranging between .056 and .112 inches.
Steel rule die cutting: Sometimes called flatbed die cutting, this type of tool includes a flat construction with blade thicknesses ranging between .028 and .056 inches. Steel rule dies can make intricate designs that require a high level of accuracy.
Bolt die cutting: Gaskets and other applications that require internal cutouts or slits on thick materials use bolt die cutting. Wall thickness ranges from .084 and .112 inches.
Singulation die cutting: To create PC boards and other components that require fine trace lines, manufacturers use these tools because they have tight allowances.

Things to Consider When Forming Die Cutting Tools

Die cutting tools must function in conjunction with a die cutting press or die cutting system. Die cutting systems range from manual hand-operated arbor presses to fully automated CNC and plate presses. For three-dimensional cutting, multi-contour trim presses are available. The material and goals of your project will determine which combination of die cutting tools and presses will work best for you.

Another consideration is cost of die cutting tools. Some die cutting tools may cost less, but will wear out quicker than more expensive alternatives. Due to this, the length of production should be kept in mind when forming die cutting tools that adequately meet your needs.

Alternatives to Die Cutting

Die cutting is just one possible technique for shaping materials into custom components. Other fabrication techniques that may be worth considering include:

Casting: placing molten metal or material into a mold to harden
Hand cutting: usiscissors or shears to manually cut a component
Milling: a rotating cung tter cuts the material about the spindle axis
Laser cutting: the use of high-powered laser to shape a product
Lathing: rotating a product about its axis and applying cutting tools