What is Knife Die Cutting?
Because die-cutting is a versatile fabrication process, it is used in a number of manufacturing processes to cut, form and shape sheet and rolled metal. A highly accurate and speedy process, custom-shaped die-cutting comes in a variety of different methods, such as flatbed, mark, punching. Knife die cutting functions well on high volume projects, producing little waste and featuring quick turnover times.
How Knife Die Cutting Works
The Knife die cutting machine is composed with a customized die which roles over a flat, depressed surface containing the female die features. The machine is fed sheet metal, paper or plastic, either from a spindle roll or flat individual pieces, which then passes through the rolling die. This cuts or perforates the desired shape from the material and deposits the finished shape down a line, while disposing of waste material in a catcher.
Because the control of the anvil can be very precise, the manufacturer can control the type and depth of cut from the die. Knife die cutting performs very well in situations where the cutting material doesn’t have to touch the fabrication liner, called “kiss cutting.” It can perform high production runs with little waste.
Types of Applications
Although Knife dies cutting works well on fabric, it is also popular for cutting papers and plastics. When customers need perforated tickets, business envelopes, or small cardboard boxes, knife die cutters can perform the operation. So as not to damage or wear down the steel dies, only soft to semi-rigid materials should be fed into rotary die-cutting machines.
Generally, Knife die-cutting is good for:Knife die-cutting CNC
High volume projects of consistent cut;
Producing less waste than other, comparable methods;
Low tolerance precision cutting;
Fast turnaround times;
Multiple process projects, because knife die-cutting can be combined with coating, embossing, lathing, and other processes.
Things to Keep in Mind
Naturally, Knife die-cutting is not suited for all fabrication projects, and there are issues to keep in mind when deciding on a method of manufacturing. For instance, because of the high speed of Knife die-cutting, products and waste can build up rather quickly. Materials handling equipment needs to be properly synced with the die-cutting process in order to keep up with production and prevent stalling and accidents. Additionally, the knife die-cutting cylinders are limited in size, as not many die-cutters can handle material wider than a few feet. Knife die-cutting projects usually handle smaller items. Softer material can be treated post-fabrication to increase strength and durability.