Understanding Die CuttingDie cutting is a fabrication process which employs specialized machines and machine tools to convert stock material by cutting, forming, and shearing it into custom shapes and designs. Both versatile and customizable, the die cutting process is suitable for a wide range of materials, including metal, plastic, wood, and composites. It also has manufacturing applications in a variety of industries, including die cutting neoprene, gasketing, die cutting paper, packaging, die cutting fabric, and producing die cut foam.
SMT single splice tapeThere are several different types of die cutting processes available today, including flatbed die cutting, rotary die cutting, and digital die cutting, with each process variant offering its advantages and disadvantages. The requirements and specifications demanded by a particular die cutting application-e.g., materials being converted, part size, desired tolerances, initial and long-term costs, lead times, etc.-help determine the type of die cutting process most suitable to use in a given situation.
This article focuses on the die cutting process as a whole, outlining the different types of die cutting and their required machines and components. Additionally, the article explores various die cutting capabilities and material considerations and provides alternatives to the die cutting process.
Through Cutting: Also referred to as metal-to-metal die cutting or thru cutting, through cutting cuts the custom design through the entire material. For example, when die cutting plastic with adhesive backing, the die cuts through the plastic face, adhesive, and backing material layers. The die cut design is fully separated from the stock material.
Kiss Cutting: For adhesive lined materials, kiss cutting cuts the custom design through the face and adhesive layers, but not the backing material layer. The die cut design is not fully separated from the stock material, but can be easily removed from the intact backing layer.
Perforating: Perforating produces a series of punched-in holes which holds the die cut design in place on the stock material. The design is not fully separated from the stock material, but can be easily detached along the perforated lines.
Scoring: Rather than cutting entirely through the stock material, scoring leaves a die impression, indent, or partial cut at a single stress point. The score produced typically only penetrates or cuts through =50% of the material which reduces the thickness at the stress point, allowing for square profile folds.
