piece of kapton polyimide tape being cut using rotary die cutting machine

Die Cutting

Die-Cutting is the process of converting materials into identically shaped pieces by utilizing a die: a ‘stamp’ consisting of sharp blades. The raw material is first mounted on a plate and then run through the machine, where the die is pressed onto the material, creating the desired shape. The speed of the machine and uniformity of the die allows identical products to be mass-produced at a rapid rate. The process also uses custom made dies, so virtually any shape can be die-cut from a material.

CGS also utilizes a more sophisticated kiss-cutting technique. It involves cutting through just one layer of material, stopping at a laminated layer or liner, allowing for paper-thin cuts.

Flat Bed Die Cutting

Flatbed die cutters use a hydraulic press to press a die down on the material, piercing through the material and forming the desired shape. This is the most popular method because the tooling costs less, making it ideal for shorter runs where the cost of a rotary tool is prohibitive. CGS also has the capability for in house steel die manufacturing, providing cost saving on new dies and quick turnaround.

 

Specifications

  • Max width up to 24″
  • Tolerances of up to +/- 0.005″, varies with material
A steel flat die with two shapes on it

Rotary Die Cutting:

Rotary Die-Cutting uses a cylindrical die on a rotary press, and a long sheet of material is fed through the press. This method is much faster than the flatbed method, however  rotary dies are more expensive. Thus, this method is ideal for longer runs because the cost of the rotary die gets diluted by the larger quantity and outweighed by the saving on time cost.

 

Specifications

  • Max size of 12″
  • Tolerance of ± 0.005″, varies with material

For more information,feel free to check out this page on wikipedia.

A rotery die with rectangle shapes

Benefits of Die Cutting

  • Save time for your production process
  • Uniformity, Accurate and Repeatable
  • Complex Shapes 
  • Lower Cost
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Die Cutting Materials

Die cutting is ideal for a variety of materials because of its efficiency, including:

Markets Served

Many industries benefit from the use of die cut materials, because it saves time and money. For example:

  • Electronics
  • Automotive
  • Medical
  • Specialty industries
  • Manufacturing
  • Powder Coating
  • Aerospace