All About Die Cutting Machines

Die cutting machines have a number of applications in the metalworking industry, such as forming, cutting and shaping metals. Using templates, or molds, the die is customized with the final product in mind. There are several traditional varieties of die cutters, including rotary, press, and flat bed die cutting machines, although newer forms have been gaining ground within the industry.

Rotary Die Cutting

Rotary die cutting machines feature a cylindrical anvil and die fabricated from a single piece of tool steel. As material is fed through the machine, a series of quick and accurate cuts modify the metal. The process is best suited for high volume projects or "kiss cutting,” in which punctures must be made through the material without piercing the fabrication liner.

In high volume production, Rotary die cutting machines can increase productivity while reducing

material waste. The machinery is well-suited for precision cutting at low tolerances and can also be used in conjunction with other processes, such as laminating and coating.

Press Die Cutting

Press die cutting machines range in size from compact personal models to large machine shop versions. They typically feature a cutting die that is raised and lowered upon the forming metal, which is supported by a flat table. The die's cutting action can be controlled by electric, hydraulic, pressurized, or manual sources. Depending upon the application, the die may cut and form a single piece of material or the material may be stacked to produce multiple copies at a time. 

Flatbed Die Cutting

A flatbed cutting machine uses varying degrees of hydraulic pressure to stamp shapes with a steel rule die. These machines are effective for making precision kiss-cuts, butt-cuts, and die-cuts to sheets and laminates.

The benefits of flatbed die cutting include lower tooling costs, greater tolerance on materials over 1/8 inch thickness, and high design flexibility. Flatbed die cutting machines are efficient for low volume orders, projects involving many different 

kinds of shapes, or applications in which no material curvature is needed.

Laser Die Cutting

Laser die cutting applies a non-thermal, fully focused beam to force material into custom shapes and sizes. The laser is typically computer-controlled and follows a pre-set CAD generated design, enabling the production of a large volume of uniform parts.

Laser die cutting is valuable for projects requiring accuracy and speed. It is also useful in creating quick initial prototypes and shaping tougher materials that would otherwise be unmanageable. It has a rapid turnaround time, and is well-suited for short run/high volume production.

Water Jet Die Cutting

Water jet die cutters fire highly pressurized streams of water that can move at almost two and a half times the speed of sound. The stream is released through a tiny opening (usually about 0.003 inches in diameter), but is able to cut through a wide variety of material.

Water jet die cutting is a relatively versatile and high precision cold cutting process. Since it uses a non-dulling cutter, maintenance costs are kept low. In addition, it produces few hazardous byproducts.