The Benefits Of Using A Rotary Die Cutter

Die cutting being a diverse fabrication process, is applied in a variety of manufacturing processes to cut, form and shape the sheet as well as rolled metal. Custom shaped die cutting is a method that is hugely popular nowadays, and comes in a several different types like flatbed, laser, press and rotary die cutting. A rotary die cutter is extremely accurate and speedy and works great on high volume projects, churning out very little waste and also features efficient and quick turnover.

The machine used for rotary die cutting comprises of a heavy cylindrical anvil that is equipped with a customized die which rolls over a depressed and flat surface containing the features of a female die. The cutter machine is fed with paper or plastic or metal from a spindle roll or flat single pieces which further passes through the rolling die. This makes it possible to cut or perforate the desired shape from the material. The cut material or finished shape is deposited down a line and the waste material produced is disposed off into a catcher. The cylindrical anvil comes with the feature of great precision and therefore the manufacturer is able to control the depth and type of the cut from the die. It is so precise, that this type of cutting can cut even such materials which should not touch the fabrication liner. This type of precision cutting which performs high production runs and produces very little waste, is termed as kiss cutting.

Rotary die cutter work well on metal, paper and plastics. Soft to semi-rigid materials should be fed into the machine, to avoid the steel dies from getting damaged or worn down. This type of die cutting is efficient for purposes like high volume projects requiring consistent cuts, low tolerance precision cutting, and CNC application, to produce very less waste, for projects requiring fast turnarounds as well as for multiple process projects. It is very much possible to combine rotary cutting technique with coating, lathing, embossing and other similar processes.

This technique is however not well suited for all fabrication projects, because it has a very high speed for cutting resulting in the products and waste materials getting built up very fast. The equipments used for material handling should be perfectly synced with the process of die cutting, to ensure that the production speed and consistency is maintained as well as to avoid accidents and stalling. The cylinders used for rotary die cutting have limitations when it comes to their size and most die cutters can only handle material which is not wider than a few feet. Only smaller items can be handled using this technique and the machines have to be fed with metal rolls, which may not be readily available for all types of metal. Post fabrication techniques are used to improve the durability and strength of softer metals. Rotary die cutters are extensively used in manufacture of medical devices and applications and are highly valued for their great precision and accuracy.

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