Exploring Custom Die Cutting Machines for Manufacturing

If you’re a person who’s interested in industrial processes, or a business seeking custom die-cutting services to improve production, you have a lot to consider and maybe even learn. After all, you should know the basics of die cutting. And there are many different machine types to choose from, plus a cinch strap full of applications. Here’s what you should know about exploring custom die-cutting services for manufacturing — and more.

Just What is Die Cutting?

While ia broad term, die cutting is essentially a fabrication process in which specialized machines are used to mass-produce cut-outs. The same shape can be repeated with the exact same dimensions.

What is a Die-Cutting Machine?

These are the machines used in die cutting. They use a die tool, typically made of metal, and range in size from table-top to significantly larger dimensions for industrial applications. The machines can cut shapes from paper, fabric, chipboard, or other materials.

What are Die-Cutting Methods in Manufacturing?

As with any manufacturing process, the right method is typically the one best-suited for the project. With that said, here are the key die-cutting methods.

  • Rotary die cutting. Here, a cylindrical blade-covered die moves in a circular motion to efficiently cut shapes. This durable method — best for high-volume projects — permits multiple and continuous shapes to be quickly cut from rolls. It’s also good for creating “kiss cuts.” This is when the main material is entirely cut through, but the die doesn’t penetrate the underlying material. Instead, it “kisses” it. 
  • Flatbed die cutting. With this, the simplest method for die cutting, a hydraulic flatbed forces down blades that cut the material. The popular method stamps out basic shapes, much like a cookie cutter. Because tools can be easily and swiftly changed, flatbed die cutting is particularly suited for low-volume jobs. It’s perfect for making die cuts to sheets and laminates.
  • Laser cutting. While this method doesn’t actually employ a “die,” it’s still commonly included in die-cutting discussions. Rather than using steel rule die blades, it’s a laser’s light that does the tricks, cutting complex shapes. Because this process is very repeatable, minute details can be accurately cut. These kinds of machines are ideal for producing initial prototypes or one-off cuts.

What are Die-Cutting Applications?

Die cutting has a variety of applications across a number of industries, including manufacturing, packaging, crafting, and more.

  • Manufacturing. Die cutting is used to efficiently and quickly cut parts for a myriad of goods — shoes, for instance. To handle the nonstop pressures of a heavy workload, large, industrial-strength machines are used.
  • Packaging. In addition to fiberboard, die-cut cardboard is commonly used to produce packaging supplies such as envelope mailers, cargo liner components and product packaging.
  • Crafting. Die cutting is often used by crafters to produce intricate cut-out pieces for home decor, scrapbooks, and more. Die-cutting permits crafters to create forms that would be challenging to make with knives or scissors.
  • Foam parts. Die-cut foam is used to produce automotive parts, gaskets, foam insulation, and more.
  • Plastic parts. Plastic sound filters can be created through die cutting that are more resistant to dust, moisture, and other contaminants than traditional fiberglass or foam filters.
  • Rubber parts. The auto industry exclusively uses die-cut rubber to create gas engine seals and rubber gaskets.
  • Fabrics. Nearly all fabrics can be subject to die cut. The process was first used, for example, to speed up the shoe-making process by cutting leather rather than punching holes manually.

In Summary 

A major benefit of die cutting is that it is customizable: tailored cuts can be created for any shape required. The process is also cost effective, fast, accurate, and versatile. It’s also durable and efficient, and some die-cutting machines can perform multiple tasks, such as kiss cutting, embossing, and laminating.

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