Flat Bed Die Cutting Services: What Do They Entail?

Curious about flat bed die cutting services? What about their alternatives? At Conversion Technologies International, we’re quite familiar with every variation of die cutting. And we’re happy to offer you some advice about how they differentiate from each other. The more you know about die cutting options, the easier it is to select the right one for your individual project. Whether you’re ready to start talking to die cutting companies or are just starting out, here’s a quick primer to these processes.

What’s the difference between rotary die cutting and flat bed die cutting?

While you’ll find several different die cutting processes available, two remain the most common. These include rotary die cutting and flat bed die cutting. Although some manufacturers specialize in one method, others offer both. Before you decide whether to process materials “in house” or outsource, it’s important to identify which process you actually need. 

Rotary die cutting pairs a cylindrical die with an anvil cylinder. The industrial die cut machine involved stretches a thin web between these two pieces. By pinching the web against the anvil, we produce consistent perforations or cuts, depending on the requirement.

Why do we like this process? It’s quite fast, for one thing, which makes it efficient. The machine rotates constantly, which results in less time wasted. If you’re looking to fulfill a high-volume order, rotary die cutting may be the right pick. It’s also quite precise—typically considered more precise than flat bed die cutting services. If you’re working on products with a more complex design, rotary die cutting may once again be the right choice.

So, when do flat bed die cutting services make sense? Let’s find out.

There are technically three different flat bed die cutting techniques: mechanical, hydraulic, and electric. They all rely on an immovable, flat base with a movable steel rule die. The die cuts customized shapes from materials on either a roll or a sheet.

The process works best with thicker materials, especially when they come in sheet form. It’s versatile, it allows for more design flexibility, and it’s more affordable than rotary die cutting. You can also use it with so many materials, including plastic, metal, cardboard, and paper. The more flexibility you need, the better this method is.

What differentiates the different types of flat bed die cutting services?

Like we said above, you’ll encounter three main types of flat bed die cutting. Mechanical die cutting involves using the more conventional equipment we described above. This is therefore the process many die cutting companies choose to focus on. Keep in mind, however—you don’t have to invest in an industrial die cutter in order to get the products you need. Experienced providers of flat bed die cutting services empower you to outsource as needed. This adds even more flexibility to what is already a naturally flexible process.

Hydraulic flatbed die cutting relies on a hydraulic flat bed press. This press pushes the machine’s blades onto the material in question. This allows them to make creative, precise cuts, ultimately providing the designs you need. Some manufacturers prefer hydraulic presses due to its increased pressure.

An electric flat bed die cutting machine replaces the traditional mechanical or hydraulic flat bed with an updated version. While the flat bed die cutter executes die cutting much like the alternatives would, it’s a bit smoother and faster. The electric equipment allows for easier automation, and it can be a bit more hands-off. Really, the process you or your provider selects is dependent on factors like preference, cost, and convenience. These are all valid flat bed die cutting options.

How many types of die cutting are there?

You might not even realize how many die cutting variations exist. We’ve already covered rotary die and cutting and flat bed die cutting; but they’re far from your only options.

Perhaps the most popular alternative to the rotary and flat bed methods is laser cutting. Laser cutting differentiates itself by relying on a laser, as opposed to mechanical cutting devices. While the old-fashioned process utilizes steel rule dies, the laser uses light. In many situations, the laser is the better choice because it can create more complex, precise designs. However, it’s also capable of destroying more sensitive materials. Therefore, it’s not always the solution we look for. It is easy to repeat, however, and if you’re working with laminate, rubber, or tape—you should give it some consideration.

In more recent years, some manufacturers have explored digital or automatic die cutting, rather than relying on an industrial die cutter. This process uses computer technology to guide the cuts. While this can expand creativity, there’s certainly room for error. Then there’s punch-press die cutting. This uses a steel rule die, forcing it through materials with a sudden “punching” motion. It’s useful for when you want a complete cut. Rather than simply separating the materials, this process completely divides them.

No matter what kind of custom die cutter you’re looking for, you have options. It’s just a matter of identifying which one serves you best—and whether or not you need a third-party manufacturer.

How do I find a third-party manufacturer?

Why not start with calling CTI? There’s no pressure—we’re happy to offer initial advice as you figure out the next steps. Check out this past automotive client’s story to see what we mean. They consulted with several firms before finding us. This was all in the pursuit of a manufacturer that could compress and laminate. While it took them a while to settle on CTI, in the end, that’s not what matters. What matters is getting the final results you need.

Give us a call at 419-924-5566 or contact us here. We can help you—starting now!