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What is Die Cutting?

Die Cut History

Die-cutting was introduced during the first industrial revolution to modernize the shoemaking industry. Before the invention, the making and cutting of shoe soles were done by hand. This process required more time and manpower, and the productivity was very low. Die cutting solves these problems. Patterns allowed shoemakers to replicate and standardize the dimensions of shoe soles. After years of exploration, die cutting revolutionized other industries and is still evolving to meet growing demand and produce more complex designs.

The die-cutting process has easily adapted to the technological age, with modern die cutting being an automatic or semi-automatic process that uses computer-aided design (CAD) and is programmed into a CNC machine. This method is widely used in the manufacturing of packaging, consumer goods, and automotive parts. The use of die cutting can be found in DIY projects and the office. Die cutting is a more efficient and faster method of producing parts and components, depending on stroke speed, feed method, and die cutting machine. This is a faster method than water jets and some forms of blade cutting. The initial cost of die cutting is easily recouped by its efficiency, speed, and superior quality.

Die Cut Adhesive Tape Applications

Many electronic components use die-cut tape. Die cut tape has strong adaptability and is widely used in computers, computer accessories, electronics, automobiles, aerospace, monitors, furniture, electrical appliances, toys, orthopedics, medical care, instrumentation, lighting, office equipment, metal manufacturing, and other fields.

Die cut tape applications include bonding, joining, mounting, sealing, fastening, connecting, shielding, gaskets, masking protection, fixed positioning, soundproofing, muting, and buffer insulation.

Characteristics of die cut products

• Efficient and fast

Due to the use of mechanized and automated production, die-cut products have the characteristics of high production efficiency, stable product quality, and controllable costs. At the same time, it can be produced and processed in large quantities and is suitable for large-scale production.

• High precision

Die-cutting products can achieve precise control of product size, shape, and dimensions, and can meet the accuracy requirements of plate angle, roundness, hole spacing, etc. Diversified product processing can be achieved through different die-cutting molds.

• Customizable

Die-cutting products can be flexibly customized, and die-cutting molds can be designed and produced according to product requirements to meet the different needs of printing, packaging, electronics, toys, medical, and other industries.

Advantages of die cut products

Characteristics of die cut products

• Efficient and fast

Due to the use of mechanized and automated production, die-cut products have the characteristics of high production efficiency, stable product quality, and controllable costs. At the same time, it can be produced and processed in large quantities and is suitable for large-scale production.

• High precision

Die-cutting products can achieve precise control of product size, shape, and dimensions, and can meet the accuracy requirements of plate angle, roundness, hole spacing, etc. Diversified product processing can be achieved through different die-cutting molds.

• Customizable

Die-cutting products can be flexibly customized, and die-cutting molds can be designed and produced according to product requirements to meet the different needs of printing, packaging, electronics, toys, medical, and other industries.

Application areas of die cut products

Die cut products are widely used in various industries, such as:

• Printing industry die cut: can produce labels, stickers, printed pendants, etc.
• Packaging industry die cut: can produce cartons, plastic boxes, leather goods boxes, shoe boxes, etc.
• Electronic industry die cut: can produce bushings, elastic seals, baffles, etc.
• Toy industry die cut: can produce mold sets, 3D kaleidoscopes, musical note greeting cards, etc.
• Medical device industry die cut: can produce medicine bottles, barrels and boxes, medical packaging materials, etc.

To sum up, die-cut products are an efficient, precise, and customized processing method that can meet the needs of different industries.

Choosing the Best Die Cutting Method

Flatbed die cutting is the simplest type and is suitable for general cutting or small batch orders. This is a very versatile process that can cut and shape any type of material. Flatbed die cutting is a systematic method of efficiently and accurately raising and lowering molds onto workpieces. If your die-cut product requires an adhesive, flatbed die cutting is the ideal process. Additionally, changeovers are simpler, faster, and easier, and tooling and die costs are far lower than other die-cutting processes.

Rapid rotary die cutting is very fast and is the most cost-effective die cutting technology. Heavy and huge rolls of raw material are fed into the rotating drum, which quickly cuts the fed material into the shape desired by the customer. Multiple impressions are cut with each rotation, producing a high-quality product.

Unlike flash die cutting, flatbed and rotary die cutting require significant adjustments when the part design changes. Both processes use traditional molds that must be reworked when designs are changed, added, or improved.

What are the common die cut products used in die-cutting processing?

In production, you will encounter a variety of die-cut products, but standard die-cut products can be divided into the following categories according to their use and structure:

1. Glue die cutting.
Generally speaking, double-sided tape has only one side of the paper with glue, and the shape is the same as the glue; there is a piece of paper without glue, the shape is larger than the shape of the glue; there is also a whole piece of glued paper directly sandwiched between the two papers, with the same shape as the glue. The original paper is separated, the materials include paper and PET, and the separation force can also be selected according to customer requirements;

2. Glue + mesh die cutting.
Mainly used for dustproof and waterproofing. Die-cut the mesh into the required shape, and paste the double-sided tape in the required shape for customers to use, generally in the form of mesh + glue + lining paper. According to different needs, silk mesh gauze with different characteristics is selected, including waterproof, non-waterproof, and metal-plated.

There are also some common forms: facial tissue + glue + screen gauze + lining paper. This product has both the dust-proof function of silk mesh and the pasting function of double-sided tape.

3. Rubber + foam die cutting.
mainly used for shockproofing. That is, the foam and glue are covered together and the mold is cut into the desired shape. The general form is foam + glue + lining paper; there is another form: lining paper + foam + glue + lining paper. This product has the dual functions of shockproof and double-sided tape.

Different foam types will also play different roles, but these products are mostly used in the processing and assembly of electronic and digital products, as well as the bonding and fixing of advertising, electronic road signs, and LED boards.

4. Glue + foam + glue + mesh die cutting.
The general form is mesh + glue + foam + base paper. It mainly functions as waterproof, dustproof, and shockproof, or it can stick electronic components and housing together without falling off or shifting.

The main function of this product is to protect decorative products from damage. Some of them are very aesthetically demanding. However, some of today’s complex electronics require dense meshes of trach holes that are small and require higher data and precision.

5. Protective film die-cutting.
mainly used to stick on the surface of other products, such as lenses for protection. This product has very strict external requirements and does not allow scratches and dirt.

Usually, different protective film materials are selected according to different usage methods and requirements. Some products are attached to other products and used during circulation to protect them. Generally, it will be torn off in the next link or process. Some protective films are directly attached to the finished product, such as mobile phone protective films, which require higher production requirements.

6. Glue + non-woven fabric die cutting.
It can be dust-proof and waterproof, has good initial viscosity and maintaining viscosity, is easy to die-cut and process, has good stability, and has good viscosity for plastics, rubber, and rough surfaces; It has good holding power under high temperatures and can be divided into white glue and black glue according to the different colors of the tape. Widely used in automobiles, digital cameras, LCDs, TVs, PDAs, notebooks, and other fields.

7. Other types of die cutting.
such as conductive cloth, copper foil, aluminum foil, etc., which mainly play the role of shielding and conductivity. This die-cut product is used between the heat source and the heat sink. By removing the air between the heat source and the radiator, the heat distribution of electronic equipment is more even and the heat dissipation efficiency is improved. Generally speaking, various thermal interface materials need to have good thermal conductivity and surface wettability.

In short, there are many kinds of die cutting products now, and the die cutting materials are also diversified. A product is not limited to one kind of material. Shanyo specializes in die cutting and has rich processing experience, which can meet the needs of different molds. All needs.

What are the processes for die cut products?

Flatbed, rotary, and semi-rotary die-cutting machines are considered industrial-scale die cutting machines and are designed for thicker, stiffer substrates and are capable of producing parts quickly Because the die-cutting process is simple, it is suitable for small or large-batch production. In industrial applications, the machine may be located directly downstream, and the starting material may be the output product of a previous process. Die cutting machines also have many features that make them a versatile and useful asset. In addition to cutting, it can perform other operations such as shaping, perforating, and scoring. The process is accomplished in a single or series of strokes on a press. Flatbed, rotary, and semi-rotary die-cutting machines are considered industrial-scale die cutting machines and are designed for thicker, stiffer substrates and are capable of producing parts quickly die cutting.

Die Cut Foam

Die cutting comes in many shapes and forms, and here are three main processes for you so you can determine which die cutting process to use for your custom labels. The three processes we will explore below are flatbed, rotary, and semi-rotary.

• Flatbed Die Cutting

Flat die cutting is a fast, efficient, and cost-effective way to produce simple parts. The process includes the use of a steel ruler mold, which consists of a series of metal strips or blades, the shape of which meets the parameters of the required parts. The cutting mold is connected to a hydraulic press or a mechanical press. Place the plate with a groove in the shape of the part as a female mold or a lower mold with an ejection material. The cutting action includes stacking the raw materials on the board and squeezing the mold and the board together.

Flatbed die-cutting machines use hydraulic presses and other lifting systems to press the die against a sheet of material. Generally speaking, flatbed die cutting is used for low-volume projects and larger-sized products. Flatbed molding machines tend to be better suited for heavier materials over 1/8 inch thick, such as felt, fiber, fabric, and metal, than most label materials.

Since it is a simple process, die cutting is suitable for low or high-volume manufacturing. In industrial applications, the machine may be located directly downstream, while the starting material may be the outgoing product from a preceding process. The die cutting machine also has many capabilities, making it a versatile and useful asset. It can perform other operations aside from cutting, such as forming, perforating, and scoring. The process is done on a press through a single or series of strokes. Flatbed, rotary, and semi-rotary die cutters are considered industrial-scale die cutting machines, designed for thicker and more rigid substrates able to produce parts at a fast turnaround. Meanwhile, manual and digital die cutting equipment are utilized to create simple and accessory parts. Its production rate is relatively slower and therefore suitable for low-volume orders.

The flatbed die cutting method is suitable for cutting thicker paper or multiple sheets of paper because it can exert greater force. A variety of materials can be processed using a flatbed die-cutting machine, and soft and semi-hard materials of different thicknesses can be processed. Flat die-cutting can be used for batch or semi-mass production, suitable for processing small production orders and large parts. Several sub-processes must be completed to use flat die-cutting to produce high-quality finished parts, as described below:

Flatbed Die Cutting Machine

• Rotary and semi rotary die cutting

Both rotary and semi-rotary types use rollers to feed long rolls and sheets of flexible material through the machine so they can be attached to the rolling dies of magnetic rollers and cut into the material.
Shanyo engineers found the half-rotation to be better suited for cutting labels because its design makes it more efficient at sharing custom labels. In the semi-rotary process, the cylindrical die rolls in a single direction, but the press moves the web back and forth as it cuts, allowing the printer to make multiple cuts on the web using a single roller. This process reduces the number of times the web needs to pass through the die-cutting system. Complete more complex cuts faster than standard rotary settings and improve turnaround time on print projects. After the roll is cut, the excess material is pulled away, leaving only the label.

Rotary and semi-rotary die cutting machines can use either solid molds or flexible molds.
A solid mold is a steel cylinder with the design built into the mold body, while a flexible mold is a thin steel plate that is bent around a magnetic cylinder. This makes flexible molds cheaper, which is great for businesses looking for custom molds for their labels.

What should I consider when die cut labels?

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