Die cutting is the method of using sharpened, thin steel blades called dies to cut out a variety of shapes from all kinds of material. There are several types of die cutting services, including rotary, steel rule, ultrasonic and laser. In rotary die cutting services, the material is crush cut between the angled blades on a cylindrical die and an anvil. Typically, the material is cut in continuous roll form, though sheets of metal can be fed through the rotary die. Steel rule die cutting services involve crush cutting the material by placing it against a cookie cutter-like tool and pressing the two with several tons of force between two parallel plates. There is also a rotary steel rule drum version that is used to cut large parts, such as boxes or garments, when accuracy is not necessary. In ultrasonic die cutting services, a metal horn vibrates in a manner similar to that of an audio speaker but at a frequency beyond human hearing. The resulting vibrations generate heat and pressure that will seal thermoplastic materials. When the vibrations are placed against a rotary die, it is possible to die cut and seal two dimensional shapes in a continuous process. In laser die cutting services, computers control 3-axis laser cutting machines. Laser die cutters come in two types: flat cutters, which cut flat sheets of material, and rotary cutters, which cut material from a web.
There are many types of steel rule dies. Conventional dies can attain the highest accuracies and the most intricate of forms and can make fold lines, scores and perforated or partial cuts. These dies are typically used to cut corrugated boxes, folding cartons, gaskets, plastics, fabric, rubber, foam and composites. The blades are held in place by high density plywood; the thickness of the blade is usually between .028" and .056”. Heavy duty steel rule dies have thicker blades (.056"-.112”) to cut through thicker, tougher materials. The blades, which can be serrated, are also held in place by high density plywood. Typical uses include gaskets, plastics, Kevlar, fabric, rubber, leather and composites. Clicker dies are perfect for cutting thicker, tougher materials but have the additional benefit of lightweight construction. The blades, running in thicknesses from .084" to .112”, are held in place by welded cold rolled steel braces. Bolt dies are utilized in applications in which internal cut out shapes or slits are needed in thicker, tougher materials. The blades are the same as the ones used in clicker dies, having the same range of thicknesses and the option of being serrated. High density plywood holds the steel blades in place but without exterior wood as is found on heavy duty dies. Bolt dies are commonly used for gaskets, plastics, Kevlar, fabric, rubber, leather and composites.
Rotary dies are typically found in the corrugated box industry, but are also commonly utilized for plastics, foam and rubber. In rotary die cutting, parts are consistently within a tolerance as tight as .02”. Ultrasonic die cutting is ideal for cutting thermoplastic material that tends to easily fray. However, this type of die cutting is limited in that only relatively thin materials can be cut, and parts have a small maximum width. Laser die cutting is very useful for cutting materials that are impossible for conventional steel rule dies to cut, such as steel thicker than .5”. Laser die cutting can also be used to cut ABS, acrylic, aluminum, brass, composites, copper and cured fiberglass.
Die sets consist of a top die machined to match the eyelet, grommet, rivet flange, etc., and a bottom die that can be roll or score set. The scored setting is utilized when the widest possible setting is necessary and it is not imperative that the appearance and smoothness be perfect. A stronger setting is formed when the prongs are embedded in the work. If smoothness and appearance of the setting are a primary concern, the roll setting is used. This setting is ideal for stiff materials such as plastic, thick leather, cardboard and metal. It can also be used in combination with a washer for soft or stretchy material.
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