Understanding Flat Bed Die Cutting And Its Functionality

Curious about the flat bed die cutting process? It’s interesting for a variety of reasons, filling a unique space in the manufacturing industry. We’ve been familiar with flatbed die cutting for quite a while at Conversion Technologies International—and we’re happy to share our knowledge.

How does flat bed die cutting work?

At its most basic, the flat bed die cutting process depends on the press. Typically, we’ll use a hydraulic or electric press to push into the material we’re cutting. On the other side, a flat surface (or “bed”) provides resistance. This creates the cut shape, or in some cases multiple shapes. Compare it to the process of using a hole punch—but at higher volumes. We can use the flat bed die press multiple times in rapid succession, allowing us to “scale” the process to a limited degree.

In some cases, you’ll hear this process referred to as “flatbed die cutting”. Most of the time, this refers to the same process. We use them interchangeably.

There are many reasons why a business owner may turn to flatbed die cutting as opposed to other types of die cutting. Let’s return to the concept of scaling. As your business grows, you’ll need to scale up over time. While this may seem straightforward in theory, in reality it often means adjusting your processes to accommodate greater volume and compressed timelines. However, you may not be quite at the point that you need larger scale production runs. Flatbed die cutting allows us to punch out the shapes quickly and accurately, accommodating smaller runs and prototypes. If you sacrifice accuracy for speed and efficiency, you run the risk of losing money (and time) to waste and corrections.

On a more basic level, flatbed die cutting simply yields better results than some of the alternatives—depending on your project and materials. No process is right for every project, but flatbed die cutting tends to be flexible enough to match the needs of many businesses. That’s why you’ll find that many third party manufacturers actually prefer it.

What operations can you perform with a flat bed die cutting machine?

Another great thing about a flat bed die cutting machine (or a flat bed die press) is its versatility. We can use this equipment for a variety of different tasks. Some of the most common uses for a flat die cutter include:

• Embossing. This process involves creating a raised design on a variety of different materials. Think of monograms—they’re often embossed. The materials we can emboss cover everything from leather to paper and metal. While we often associate embossments with decorations, in some cases they have functional purposes as well. You can label a product through embossment—and in fact, they create braille through embossment.
• Debossing. Simply put, debossing is the reverse of embossing. Rather than creating a raised imprint, you’re creating an indented designed. Functionally, debossing offers many of the same applications as embossing.
• Cutting. Obviously, this is one of the primary functions of die cutting. The flatbed die cutting process is precise and detailed, allowing us to execute complex designs in a systematic manner.
• Scoring. In a manufacturing context, scoring allows us to create scratches and grooves. This not only allows us to create specific designs—it also enables us to manufacture products that bend and fold as needed. We may score products in order to facilitate a guideline to follow in the next process—painting, for example.
• Perforating. Perforating is exactly what it sounds like: You’re creating holes in a product. These may, similar to scoring, act as guidelines, or offer greater functionality in accordance with specific designs. It really depends on the project.

In addition to leather, paper, and metal, we can also apply flatbed die cutting processes to fabric, cardboard, and more. Remember—when it comes to manufacturing, the greater the flexibility, the better!

What’s the difference between flatbed die cutting and rotary die cutting?

Not all flatbed die cutting alternatives stand up in comparison—but the most prominent is rotary die cutting. So how do they differ?

As the name implies, flatbed die cutters use flat presses. They move up and down, punching out the material as we discussed earlier. If you’re in that “in between” phase of your business, scaling up while not quite needing large scale orders, flatbed die cutters could be your solution. If your priority is large scale runs, however, a rotary die cutter could be the better bet.

A rotary die cutter operates using a cylindrical press rather than a flat one. Material passes through the cutting machine, and the cylindrical die cuts out your desired design. While flatbed die cutting is appropriate for thicker materials, rotary die cutting isn’t quite there. You’ll stick to thin materials with this machine—it’s the best way to maintain the integrity of the results.

The good thing about this contrast is that thicker materials do typically correspond to smaller runs, while thinner materials are better suited for larger runs.

Should I invest in a flatbed die cutter?

Here’s the thing: You don’t have to invest in your own flatbed die cutting machine. The better option for many business owners is working with a third party manufacturer like CTI. We have not only the equipment, but the expertise necessary to execute your desired project. Call us at 419-924-5566 or go here to learn more!