What is Die Cutting?
Die-Cutting is the process of cutting material 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, which cuts out 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 utilize kiss-cutting technique, simply put, is a more sophisticated way of die-cutting. It involves cutting through just one layer of material, stopping at a laminated layer or liner, allowing for paper-thin cuts.
Die Cutting Methods
Die cutting comes in many shapes and forms, there are two major processes that you should know, so you can figure out what die cut process to use for your materials. The two main processes that CGS use are flatbed, and rotary.
Flat Bed Die Cutting
Flatbed die cutters use a hydraulic presses and other lifting systems to press a die down on the material, die cut through the material and form the desired shape. This is the most popular method as it only uses a less expensive steel-rule dies. This method is ideal for shorter runs where the cost of a rotary tool is prohibitive. CGS also has the capability for inhouse steel die manufacturing, providing cost saving on new dies and quick turnaround.
Rotary Die Cutting:
Rotary Die-Cutting uses a cylindrical die on a rotary press where a long sheet of material is fed through the press, which holds a rotary tool that will cut out shapes or alter the material in different ways. Rotary die cut is much faster than flatbed method, however the rotary dies is also much more expensive. Thus, this method is ideal for longer runs where, the cost of rotary die gets diluted by the larger quantity, and out weighted by the saving on time cost.