Rotary cutting has a number of distinct advantages:
The depth of cut can be controlled precisely between the anvil and the die which makes it ideal for 'kiss' cutting and results in long life and clean cuts for 'thru' cutting.
Cuts tend to be consistent since the dies are machined from a single piece of tool steel. The blades will break or wear out before moving. It is possible to make a bad cut by deforming the material going through the die.
Material can be processed at high rates of speed. The limiting factor for productivity rarely lies in the cutting. It is usually the material handling, the size of the rolls, or other in-line processes that limits the process speed.
Rotary processes lend themselves to being combined. It is not usual to combine rotary cutting with coating a substrate, laminating a foam material, and embossing it before die cutting.
Because processes can be stacked, the register (timing) between each process can be maintained. A Flexo printed label is an example of this. Each color is a separate rotary process as is the cutting out of the label. When combined in a single rotary process, the relationship between these steps can be adjusted and an aesthetic product is produced at high speeds.
Because of the way a rotary die is constructed, there is less make-ready involved. The results are faster setups, greater productivity, and less scrap. In the broader sense of the word, rotary is a high quality process.
The cost of tooling is moderately higher than steel rule but lower than male/female dies.
Because the material is fed in roll form at high speeds, there is less handling and fewer opportunities for contamination of the product.
Dies can be made and delivered to us in 7 to 10 working days, usually more quickly than material can be obtained.
Given these features, rotary die cutting is ideal for:
High volume applications,
Kiss cutting applications,
Combining with other processes,
Precision cuts up to +/- 0.002 per inch.
Low piece part cost (based on volume),
Just-In-Time application
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