What is Die Cutting?
Die cutting is a broad term, but in crafting, the act of die cutting refers to a process in which you use a machine to mass-produce cut-out shapes.
You can create the same shape, with the exact same dimensions, over and over without using scissors, stencils, or a craft knife.
It saves time and makes your cut-out shapes look professional and consistent every time.
Die cutting is a mass production method used to cut out shapes by shearing materials like paper and chipboard with a die.
A die is a specially designed tool with sharp edges that matches the two-dimensional shape of the desired cut-out.
This process is similar to using a cookie cutter to shape dough. Die cutting can be applied to a variety of materials, including paper, fabrics, rubber, fiberglass, metal sheets, foam, wood, and plastics.
Die cutting originated during the first industrial revolution, initially transforming the shoemaking industry.
Before its invention, shoemakers cut soles by hand, a labor-intensive process with low production rates.
Die cutting introduced patterns that standardized and streamlined the production of shoe soles.
Over time, this method revolutionized various industries and continues to evolve to meet the demand for more complex designs.
Modern die cutting has adapted to technological advancements, now utilizing computer-aided designs (CAD) programmed into CNC machines for automatic or semi-automatic operations.
It is extensively used in packaging, consumer goods, and automotive parts manufacturing, and also finds applications in DIY projects and office settings.
Die cutting is efficient and fast, with performance depending on stroke speed, feeding method, and machine type.
It is generally faster than waterjet cutting and some blade cutting methods. Despite initial costs, die cutting’s efficiency, speed, and high quality make it a cost-effective choice.
Die cutting is a straightforward process ideal for both low and high-volume manufacturing. In industrial settings, the die cutting machine can be positioned downstream, processing material that is the output of a preceding process.
This versatility allows the machine to perform additional operations such as forming, perforating, and scoring, all through single or multiple strokes on a press.
Industrial die cutting machines, including flatbed, rotary, and semi-rotary models, are designed for thicker, more rigid substrates and offer fast production rates.
In contrast, manual and digital die cutting equipment are suited for creating simpler parts and accessories, with slower production rates making them better for low-volume orders.
What Is A Die Cutting Machine?
Die cutting machines or card making machines are machines that cut shapes out of paper, chipboard (like cardboard but thicker and more dense), fabric, and other materials.
Most people who die cut regularly have personal die cutting machines that are about the size of a small toaster oven.
These machines can sit on top of your crafting table or workspace or can be stored in a small area and brought out when needed.
There are even tiny tabletop versions like the Sidekick or Mini Evolution and compact folding versions like the Sizzix Big Shot Foldaway.
Just like any other appliance or tool, there are a variety of brands of die cutting machines, and each differs slightly from the other.
You can also check out this resource for die-cutting machines. It will give you an overview of different styles so you can choose the right machine for your needs.
Types of Die Cutting Machines
Die-cutting machines come in various types, each suitable for different applications.
Manual: Manual die cutters use steel-cutting dies activated by a lever. These compact machines are ideal for home use or desire!
Digital: Digital die cutters are another home-friendly option for cutting paper shapes. They require a computer cartridge containing an image and electricity to operate. Instead of a steel die, a sharp blade cuts the material.
Industrial: For large-scale manufacturing, industrial die cutters are used. These machines automate the cutting process to speed up the production of shapes.
What Are Die Cutting Machines Used For?
Though die cutting machines vary (you’ll want to read the machine specs before purchasing) all die cutting machines cut paper.
Most also cut felt, foam, thin fabric, and vinyl- though it’s to be noted that only steel-rule dies can cut chipboard. Some can even cut corkboard, leather, rubber, and sponge!
Die cutting machines can be used to make stickers, envelopes, stand-up cards, gift tags, treat bags, party favors, shaker cards, pillow boxes, and more.
They are used by card makers, scrapbookers, paper crafters, quilters and general crafters. They are even used in classrooms to facilitate learning and create projects.
Die Cutting Tools
Rotary die cutting machines operate continuously at lower cutting pressures and constant speeds, making them well-suited for being positioned directly downstream from a previous process.
These machines are ideal for producing simpler and lighter parts, offering versatility for various materials and a quicker turnaround than flatbed die cutters.
The stock material, or web, in sheet or roll form, moves through the cutting assembly. This assembly consists of a rotating cylindrical die mounted on a rotary press and an anvil cylinder pressing against the rotary press.
As the web passes between these rotating cylinders, it is compressed, allowing the sharp edges of the die to cut through the material.
A rotary die cutting machine can perform both full and partial cutting. While the fundamental steps are similar to those in flatbed cutting machines, the mechanism of the cutting assembly differs.
There are two types of rotary dies, chosen based on the material properties and economic considerations.
Flexible Rotary Die
Flexible rotary dies are crafted from thin steel sheets with engraved patterns that form the cutting edges, wrapped around a magnetic cylinder.
They are suited for low pressure and shallow or partial cuts. The thin cutting sheet can be replaced according to the specific part to be cut, and the magnetic cylinder can accommodate various flexible dies.
These dies are cost-effective and easier to manufacture, with minimal downtime during replacement. However, they are less durable compared to solid dies.
Solid Die
A solid die features engraved, abrasive patterns directly on the rotating cylinder. Designed for higher pressure applications, it can handle deeper cuts on thicker and multi-layered materials due to its ability to exert greater forces.
Solid dies can be sharpened when worn out, offering greater durability and flexibility. However, they come with higher initial and maintenance costs.
When operating a rotary die cutting machine, several operating and material conditions must be considered:
- The tangential speed of the rotating cylinders and the speed of the web must be the same. This ensures proper placement of the material between the two cylinders, resulting in precise and uniform cuts through the entire length.
- The clearance between the rotary press and anvil cylinder must be optimized according to the thickness and compressibility of the stock material. If the clearance is too narrow, higher cutting pressure will be applied which may cause fatigue in the machine components. On the other hand, if the clearance is too large, the cutting pressure is not sufficient to cut the sheet properly. Large clearances are suitable only for partial cutting.
- The rotary die to be selected must have a blade width and angle that is optimal for the material to be processed. Thicker and more rigid materials require a wider and steeper blade.
Semi-rotary Die Cutting
This type of die cutting machine is similar to a fully rotary die cutter but utilizes only one cylinder containing the die for cutting.
The semi-rotary die cutting equipment is programmed so that the cylinder moves in a single direction while the web moves back and forth.
This combination of cylinder and web movement allows for multiple cuts, eliminating the need for an additional cylinder.
Semi-rotary die cutting machines are generally less expensive than fully rotary and flatbed die cutters. However, they are limited to low-pressure applications.
While industrial-scale die cutting machines have been discussed, the following equipment is used for creating simpler parts with a relatively low production rate, making them suitable for small-scale applications:
Manual Die Cutter
Manual die cutters operate by pushing a crank lever, which presses the steel dies onto the substrate to cut out the finished part. This method is ideal for soft materials like paper.
Manual die cutting is particularly suitable for producing auxiliary items. This equipment is compact and portable, commonly used in homes, offices, and craft spaces.
Digital Die Cutter
A digital die cutter is a versatile machine controlled by computer software or cartridges. Unlike traditional die cutters, it uses sharp blades instead of steel dies and is powered by electricity. Digital die cutting machines, like manual ones, are suitable for indoor installation.
Die Cutting Procedure: Step-by-Step Guide
- A steel cutting die is placed on a wood instead of a printing plate of the same height.
- A metal sheet is placed on the press bed in place of tympan paper and packing, providing a solid base for the die to cut into.
- The initial procedures are similar to those used in letterpress printing, but since no ink is used, the rollers are removed before printing begins to prevent damage to the rubber rollers.
- The die is locked into the chase, and the chase is inserted into the press to attach the metal plate/backing to the press bed.
- The press is started, and cutting begins.
- After cutting, the carved form is ejected. The proof mockup is placed underneath, aligned with the cut sample.
- Any necessary tweaks are made, and the cutting process continues.
Die cutting can add a unique touch to any print job, serving as a decorative accent or a practical addition to a design.
However, it’s important to consider the limitations of die-cutting. Constraints may arise when using intricate shapes or patterns, and there’s a minimum required size for die cuts.
The choice of paper and die-cutting options can also impact the final product. For instance, thinner paper cuts more smoothly, while heavier stock can result in less precise edges. Cotton paper, in particular, tends to fray.