Die Cutting
The simplest analogy for this process is to think of a biscuit-cutter for making shapes from dough in the kitchen. Just as easily applied to paper or plastic,die cutting is a simple process that involves a sharp edge being brought down onto a thin material to cut as hope in a single step. A die-cutting tool has two functions: the main function is to cut a shape from the sheet; the second is to apply creases to the material to allow it to form an accurate bend. The creases are necessary when constructing three-dimensional shapes and integrated hinges from a sheet.
Volumes of production
From small batches of around a hundred units, to thousands.
Unit price vs capital Investment
The low cost of tho cutters makes this a highly economical process even for small runs Sheets of material may be fed individually but if the material comes on a roll there will be a massive reduction in the cost of the final products.
Speed
Die cutting is one of the predominant manufacturing processes for packaging, with production cycle times of up to thousands of products per hour Unlike in mould products, the cutting speed is not affected by the complexity of the shape.Assembly, however, is more labour- intensive.
Surface
The surface is dependent on the material. The cut edge, however, is clean, precise and with a very, very fine radius where the cutter has cut through the material. As you might expect, the sheets can be finished with various forms of printing or embossing, or a combination of the two.
Types/complexity of shape
The complexity of the shape is really dependent on the size of the cuts. Very fine slots of less than about 5 millimeters can be difficult to cut. One of the design issues to bear in mind is that the excess plastic around the part needs to be removed and cleaning plastic from fine holes can be difficult.
Scale
Most manufacturers should have no problems at all in cutting sheets of up to 1,000 by 700 millimeters, and some are able to go slightly larger and cut straight from a roll. However, material choice is more limited if it comes on a roll. Printing on large sheets, above 1,000 by 700 millimeters, may be difficult due to the limited availability of large scale printing machines.
Tolerances
Very high tolerances.
Relevant materials
A large proportion of the material used is polypropylene due to its ability to form a strong integral hinge. Other standard materials include PVC, polyethylene terephthalate (PET), paper and all sorts of card.
Typical products
Die cutting is extensively used for packaging, especially boxes and cartons. For this type of product, assembly is required to construct the three-dimensional structures. Other, more product-focused, applications include lampshades that require complex assembly (pictured),
toys and even furniture.
Similar methods
For cutting flat sheets, try laser (p.46) or water-jet cutting (p.42).
Sustainability issues
Die cutting can be more economical in terms of material use if shapes are nested and material wastage is reduced. The nature of the material determines whether waste (of which there will be
a considerable amount) can be reheated and recycled.
