1. What is a custom die cut?
Traditional die cutting is a cutting process for post-processing of printed matter. According to pre-designed graphics, the die cutting process can make printed matter into the mould. Such as custom business cards and hang tags mould. The cut shapes are controlled by operating the machine. However, the traditional die cutting manufacturing process is still very complicated. It ensures that we can control the shape of the print. Prints can be custom shaped. It makes its shape no longer limited to straight edges and right angles. It also provides technical support for the emergence of some business cards and hang tags.
First of all, we must develop product drawings. According to the requirements of the product design, we can determine the specific shape of the custom die cut. For example, the membrane switch manufacturer can produce membrane switches based on design drawings. Under the action of pressure, we roll and cut printed materials or other shaping materials into the specific shape required.
2. Die cutting manufacturing process
2.1. The last edition of custom die cut
The die cutting process of manufacturing a membrane switch panel mold is very complicated. First, we can proofread custom die cut. After that, we roughly observe whether the custom shape and cut shape meet the requirements of the design draft. Are the positions of steel wire (crimping knife) and steel knife (die-cutting knife) accurate? Whether the cutting line for slotting and cutting uses the whole line. Whether the corner of the line is around the corner.
In order to help waste removal, the adjacent edges have to enlarge the connection part. Whether there is a sharp angle at the joint of the two lines. Whether there is a problem in which a bright line ends in the middle paragraph of another straight line. As soon as the above problems occur, we should immediately notify the plate makers to make corrections. It avoids wasting more time. Then, we can install the fixed custom die in the frame of the cutting machine. At the same time, we can initially adjust the position of the version.
2.2. Process of die-cutting indentation
(1). adjust the pressure
To adjust the layout pressure, we should adjust the pressure of the steel knife at first. After padding the paper, we should turn on the embossing to flatten the steel knife. Then we use a paperboard which is larger than the die-cut layout to test.
(2). determine the rules
Under the cut on the cardboard, we can increase the pressure or reduce the number of layers of the paper. It makes the cutting line pressure on the layout consistent. Generally, the steel wire is 0.8mm lower than the knife wire. In order to the steel wire and the steel, the knife can obtain the ideal pressure. We should adjust the pressure of the steel wire, according to the nature of the die-cut cardboard.
We usually calculate the thickness of the padding paper which based on the thickness of the die-cut cardboard. That is the thickness of the pad paper = the height of the steel knife-the height of the steel wire-the thickness of the die-cut cardboard.
(3). stick the rubber
After adjusting the layout pressure, the die-cut plate is fixed. When we determine the location, the custom die cut product is usually placed in the middle. Rubber bullet plugs can place on both sides of the leading steel knife base. We can use the excellent recovery of the rubber band to push the separated cardboard out of the blade.
(4).Test die cutting
After the above work completed, we should die cut the proof first.
(5). Official die cutting
Then, we conduct a comprehensive inspection to see if the indicators meet the requirements. After the full-time inspector signs, we confirm the sample. Mass production can be carried out.
(6). Waste removal
During the production process, operators should conduct product inspections from time to time.
(7).Finished product inspection
It is mainly compared with the proofs to see if there are problems to be solved in time. The die-cut product can remove with excess scrap. Then we can sand the edges with burrs to make them smooth and without burrs. Subsequently, Then select and inspect the finished product, which can remove defective products.
(8).Determine quantity and pack
Finally, we can complete the steps of points, packaging, acceptance, and storage.
3. What are the main types of die cutting manufacturing process?
3.1. Steel knife die cutting
It is a commonly used cutting form in the membrane keypad. The method is make a profiled “steel knife” according to customer specifications. Then we cut out the parts by stamping.
3.2. Rotary die cutting
Die on a rotary is mainly used for bulk coil cutting. Die on a rotary is suitable for soft to semi-rigid materials. The shaping material is pressed between the cylindrical die and the blade on the cylindrical anvil, which can achieve cutting. Cut out shapes in various.
Advantages of rotary die cutting:
(1). It has strong cutting capability, high precision, and small tolerance.
(2). Fast processing, high output and low material loss
(3). It suitable for “kiss cutting” projects
(4). Low volume discounts
(5). It can combine with coating and lamination methods
3.3. Laser Die Cutting
We use it when traditional steel die-cut cannot cut the materials. The cutting process is clean, and no cutting heat is generated, which is suitable for large-scale cutting.
When the cutting capability of the material cannot be achieved with Steel knife die cutting. We recommend laser cutting.
Unlike other cutting processes, laser cutting uses non-thermal laser beams to shape customer-specified materials. It allows for custom shapes and sizes. The laser die-cutting head is used for cutting according to the preset path generated by CAD, which is suitable for mass production.
When the customer needs cutting accuracy and speed, customize laser cutting is the ideal solution. This process can use for high-hardness parts. The materials used for these parts are hard, so other die-cutting processes cannot complete the cut. At the same time, this process is also commonly used for rapid proofing.
Liner cutting, also called cutting, dies. It can shape or transform the selected material (sheet or tube) into the desired shape and size. Professionals in companies can assist in processing gaskets. They design, cut, and deliver the finished product in order to meet the customer’s project requirements. We can use a variety of cutting dies methods. These include flat knife cutting, die on a rotary, laser cutting, and water beam cutting so that the pads meet the respective specifications.
4. What kinds of machines commonly use in the die cutting manufacturing process?
The die cutting method and process of the die is critical in the product production process. So, it must be no errors. The machine which is cutting the product is also essential. It mainly divided into four types of die cutting.
4.1. Flat die cutting machine
It has a more straightforward structure, easier maintenance, and lower price.
Besides, it has a high speed of production, high accuracy of the machine, automatic removal of waste.
The machine exists such a problem, such as low production speed, poor safety, high labor force, and requires individual operating skills.
Besides, higher prices and more significant initial investment in equipment is also a big problem.
4.2. Round die-cutting machine
Advantages: it has high production efficiency and high cost-productive.
Disadvantages: Die-cut version is expensive to make. Because they generally need to customize high quality cylindrical die.
4.3. Circular flat die cutting machine
Disadvantages: die cutter life is short.
Advantages: it less limited by cutting tool appliances.
4.4. Laser die cutting machine
It mainly uses the high thermal energy of the laser. The high thermal energy of the laser ablates the die-cutting board. It will form a gap. The slits are aligned and the slit width is consistent. Moreover, it is a fully automated operation with low cost and high efficiency. It is the best alternative to the traditional production of membrane switchboards. At the same time, it can be used for cutting and cutting carton models. Therefore, it can widely use in the packaging industry.
5. What are the advantages and disadvantages of laser die cutting machine?
5.1 Its advantages:
(1). High quality and precision: it is a fully automatic laser cutting. No vibration deviation, high accuracy, and stability are its characteristics. You can even achieve a kiss cutting effect. The computer has controlled the production of the membrane switchboard. It operates by using a laser die cutting system. Its cutting accuracy can reach ± 0 05mm, and the complexity of graphics does not limit it. Therefore, the cut-out multi-layer boards, special-shaped boards, and die-cut boards without mottled sides are very exquisite.
(2). High speed and high efficiency: The machine has the advantages of large format and non-contact type. Moreover, when workers are proficient in laser technology. Its production of the die-cutting board is more than one times faster than that of the sawing machine. Its short production cycle, low labour cost and high cost effective are its advantages.
(3). Simple and easy to use: It can complete the cutting knife seam design on the computer. Various tool gap parameter settings generated, which based on the software. It is easy to learn and use. It reduces the impact of the loss of skilled workers on the regular operation of the enterprise.
(4). Repeatable processing: Because it can store the computer-made laser cutting system. Furthermore, it can use the laser cutting system to customize the laser cutting program. So when we need multiple identical membrane switchboards for mass production. Just call the program and cut it, and you can do it repeatedly. And because of the precise control of the computer laser cutting system. It dramatically increases the die cutter life.
(5). Not limited by cutting tools and shaping materials, the cut-out shapes of the customized die can be diversified.
5.2 Its disadvantages:
(1). High threshold for laser technology. The company increases the requirements for the overall quality of workers.
(2). The initial investment of laser equipment is significant.
(3). The high of die cutting methods testing