Page 12 - THE INDEPENDENT

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The previous chapter showed how industry benefitted massively by these manufacturing processes but in chapter two we will explore die cutting and the other benefits that this manufacturing process offers.
Within manufacturing, die cutting is also referred to as blanking. It is a stamping process in which shapes are cut from sheet materials. Although originally created for the shoe industry, the die cutting process is now primarily used for packaging and is the most cost effective way of cutting complex shapes from most non-metallic sheet materials, which includes paper, card, plastic, felt and foam.
Die cutting is ideal for creating unique and intricate packaging solutions that are complex in shape. Most boxes, cartons and trays are made in this way. Die cutting is a major application within the stationery industry, cutting out labels, envelopes, papers, pre-scored cards and pressure-sensitive adhesive-backed labels.
STEEL RULE DIE CONSTRUCTION:
Steel rules are mounted into a wooden die which is typically laser cut so it can easily be replaced.
The steel rules pass all the way through the wood to ensure that all the energy produced by the press goes directly into the cutting action. This construction gives these dies a long lifespan and therefore the quality of cut remains high and repeatable over large volumes. This fact remains true with the domestic steel rule dies (see chapter 4) available for use with compatible die cutting machines, however the materials they are used to cut does impact on their performance over time.
THE DIE CUTTING PROCESS:
A sheet of material is loaded into the cutting plate and the cutting plate rises up to meet the steel rule dies, cutting through the sheet material. The foam that surrounds the steel rule and the rubber pads on the cutting plate help to eject the material from the die which prevents the machine from jamming.Typically, the pressure required to die cut can be anywhere between 5 & 15 tonnes
(5.5 – 16.5 US tons), some die cutters can reach up to 400 tonnes (441 US tons), which allows for sheet material to be cut simultaneously. The pressure used is determined by the type of material and thickness that needs to be cut.
Scoring, kiss cutting and perforating are equally precise but as with all die cutting machines, both industrial and domestic, the choice of material can alter the quality and accuracy of the cut. Some materials resist certain cutting techniques and kiss cutting can result in a halo around the perimeter or cause laminated materials to delaminate (layers separating or peeling off).
Within the die cutting manufacturing industry, steel rule dies are used. These are very cost
effective, and multiple dies can be grouped together and mounted onto a single die to maximise output. However, although the intricacy and complexity of steel rule dies may not have a major impact on cost, there are limitations that need to be taken into consideration. On large scale projects these limitations do not have a major impact on production but smaller dies in manufacturing are not capable