What is die cutting?

Die cutting is a large-scale process in which materials such as paper and cardboard are cut through a die, a tool specially designed to cut or shape materials. The mold has sharp edges to pierce the material and has a finished two-dimensional shape. The die-cutting process works on the same principle as a cookie cutter, cutting the dough into small pieces. Die-cuttable materials include paper, fabric, rubber, fiberglass, sheet metal, foam, wood, and plastic.

Die cutting was introduced during the first industrial revolution as a way to modernize the shoe industry. Before it was invented, shoemakers needed to sketch and cut the soles by hand, a process that required more time and labor, and very low productivity. Die cutting solves these problems. The creation of shoe molds enables shoemakers to replicate and standardize the dimensions of the soles. After years of exploration, die-cutting technology has revolutionized other industries and is still evolving to meet growing demands and manufacture more complex designs.

The die-cutting process has easily adapted to the technological age. Modern die cutting is an automatic or semi-automatic machining process programmed into a CNC machine using computer-aided design (CAD). It is a method widely used in the manufacture of packaging, consumer products, and auto parts. The use of die-cutting can be found in DIY projects and offices.

Die-cutting is a more efficient and faster method of producing parts and assemblies, depending on the speed of the stroke, the method of feeding, and the type of die-cutting machine. It has been found to be a faster method than water jet and some forms of blade cutting. The efficiency, speed, and excellent quality of die-cutting make the initial cost of die-cutting easy to recover.

Since it is a simple and straightforward process, die cutting is suitable for low or high-volume production. In industrial applications, the machine may be located directly downstream, and the starting material may be the output product of a previous process. The die cutter also has many features, making it a versatile and useful asset. Besides cutting, it can also perform other operations such as forming, punching, and scoring. This process is done in one or more strokes on the press.

Flatbed, rotary, and semi-rotary die-cutting machines are considered industrial-scale die-cutting machines designed for thicker and stiffer substrates and capable of producing parts quickly. Make simple accessory parts using both manual and digital die-cutting equipment. Its production speed is relatively slow, so it is suitable for small batch orders.