Advantages of Precision Die-Cutting - SMI - Seals Methods Inc.

Precision die-cutting is a highly efficient manufacturing process because it saves time and money, increases productivity, and gives you consistently accurate results every time for parts that range from miniature washers to large gaskets. Non-metallic materials are continuously fed into die cutting equipment, and parts with tight tolerances are continually output.

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Industrial die cutters are widely used in manufacturing, specifically in the packaging process. But precision die-cutting machines have grown more advanced over the years. Today, industries ranging from automobile and medical device manufacturing utilize die cutters in their operations as well.

Two general forms of die-cutting Seal Methods Inc. uses are Rotary and Flatbed Die-Cutting.

Rotary die-cutting uses custom-made cylindrical dies and a multi station rotary press to convert a wide array of materials from roll stock to a finished part.  These parts can be offered in finished rolls with parts kiss cut to a liner, or individual parts.  

Generally, rotary die-cutting is good for:

• Multiple process projects; rotary die cutting can be offered with coating, embossing, creasing and other processes. 
• Multilayer laminations, with precision die cut parts indexed on a liner.
• Intricate mid to High volume parts

Flatbed die-cutting is the process of cutting or perforating the desired shape out of material using a hydraulic flatbed press. 

Generally, flatbed die-cutting is good for:

• Larger sized products
• Cutting products from sheet or roll materials
• High precision cutting of materials over various thickness
• Low to high volume projects

Seal Methods Inc. uses precision die-cutting technologies, utilizing machines that can feed one or multiple materials into a die-cutting station, which features a rotary die and a hardened anvil cylinder. The rotary die cylinder, which contains the part image, presses against the hardened anvil cylinder&#;s surface and cuts out a specific shape using the raw material in between.

The advantages of die-cutting include its potential to create nearly any shape with precision rotary die-cutting technologies and equipment, including specific die cuts, slits, or perforations. The die-cutting process is designed to produce high-tolerance parts at extremely high volumes.

At Seal Methods Inc. we manufacture gaskets, seals, tapes and precision die cuts for a wide array of industries. Using flat bed and rotary presses, we are able to cut any volume of foam, film, fabric, foil, rubber elastomer, plastic, hi-temp composite and more. Our long history aligns us with premier raw material manufactures like 3m, Saint Gobain, Rogers, Gaska, Nitto Denko, Dupont, and more. By maintaining a variety of equipment, we are able to fully optimize processes to meet specific applications. Our team has been providing precision die cut products for over 40 years and can select the ideal process for a given part material, size, volume, and dimensional tolerance.

Our versatile manufacturing capabilities also include rotary conversion, slitting, sheeting, laminating, CNC knife cutting and molding. As an ISO/IATF registered manufacturer, customers can be assured that their parts are held to stringent quality standards. In-house testing and inspection capabilities include a range of adhesion and material testing as well as dimensional inspection in accordance with all customer specifications. For additional information about our precision die cutting capability, see the table below, or contact us directly.

Here are a few of our precision die-cutting Applications

• Sealing
• Vibration Damping
• Electrical Insulation
• EMI/RFI Shielding
• Gaskets
• Insulation
• Rubber Goods
• Rubber Parts
• Washers

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In flexography printing, die cutting plays an important role. With die cutting, the print job is faster and requires less hands-on effort, which can be difficult with miter saws and other cutters. Because die cutting eliminates the need for precision cuts, it is an efficient and accurate printing method. Furthermore, die-cut paper can be handled and printed on more easily due to its slimmer thickness. Lets look at the advantages and disadvantages of rotary die cut machine in detail.

What is Rotary die cut?

Printing with rotary die cut involves cutting a die into a variety of shapes, such as circles, squares, and other patterns.

Compared to traditional printing methods, this allows the printer to produce intricate and detailed prints.

There are two types of rotary dies.

1. Solid die
2. Magnetic die

Advantages:

There are a variety of designs that can be printed using the rotary die cut, which is a simple, efficient, and affordable printing method.

The fact that rotary die cut printing produces more accurate cutting may make it a better choice for flexography printing.

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As a result of die cuts, less offset is created, and the finish is more efficient.

Furthermore, die cuts can be customized to produce unique designs that are hard to replicate without special equipment.

Intricate designs and custom shapes can be created with rotary die cuts.

Rotary die cuts are ideal for those who want to create unique pieces since they are hard to replicate using other methods.

There are a variety of rotary die cutters available for small businesses and amateur printers.

Their affordability and ease of use make them an excellent choice for those who want the best results.

As rotary dies produce a precision product, they are a popular way to cut products.

Additionally, rotary die cuts offer many advantages over standard cutting techniques when it comes to response time and accuracy. 

Disadvantages:

Although magnetic rotary die is less expensive than a solid rotary die, but the rotary die cut method has its own cost and is not feasible for small volumes.

It may be necessary to make specific settings in order to produce accurate prints with this product.

In particular, precision is a challenge when using the die cut feature.

Due to its die-cut feature, rotary die cuts may be less versatile than other printing options.

FAQs:

What is the difference between Rotary die cut and flexography?

Rotary die cut machines are used to cut intricate designs, while flexography is a printing process where images are reproduced using flexographic plates.

Conclusion:

Rotary die cut in Flexography is a process where high-quality images are cut out of flexible materials, such as vinyl and paper.

This method can be used to create intricate designs and patterns that would be difficult or impossible with other types of graphics production methods. 

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