Home > contract manufacturing > Flatbed Die Cutter Qualities And Alternatives

flat bed die cuttingIf you’re curious about the flatbed die cutter—and maybe a few of its automatic die cutting alternatives—you’ve come to the right place! At Conversion Technologies International, we know exactly how to match this process to the right project. Check out our tips, questions and answers below.

 

 

 

 

How does a flatbed die cutter work?

When working with a flatbed die cutter, we can cut through both metal and non-metal materials. The process depends on customized steel rule dies, which we attach to a flatbed press. Depending on the configuration of the specific flatbed die cutting machine, we can work with different strategies. Typically, we reserve flatbed die cutting for commercial projects, as it allows us to produce quality results on a large scale.

Usually, die cutting equipment includes:

  1. The feeder. We sometimes refer to this as “the loader”, and it uses motions including pulling, sucking, and pushing. It transfers the product from feed trays or unwind stands to the processing mechanisms. Additionally, the feeder can register individual sheets of material for the next part of the machine. This ensures we’re positioning the section correctly and it prevents errors in the long term.
  2. The cutting station. That next station? It’s the cutting. Here, the steel rule die remains positioned on an upper plate, or “cutting head”. And the lower plate, or “press head” works in conjunction with the steel rule die’s specific design. The cutting head moves at a vertical angle, applying pressure until the edge cuts the material. This is how you get the results you’re looking for.
  3. The stripping system. This system removes the leftover waste materials. Meanwhile, the die cut designs move down the line for further processing and perfecting.
  4. Timing and control systems. Here, these systems monitor the cutting the process. This way, the flatbed die cutter can make adjustments in order to avoid inconsistencies and flaws.

Once you know how the broad flatbed die cutting system works, you can explore more customized configurations—and alternatives.

What’s the difference between a die cutter and a cutter plotter?

The main differences between a flatbed die cutter and a cutter plotter lie less in the results, and more in the mechanics. Above, we walked through the basic workings of an industrial die cutting machine. A cutter plotter works on a digital level. The flatbed die cutter depends on a small, physical, customized die to create a lot of small components. The cutter plotter, in contrast, follows a predetermined path with a blade. It creates a smaller number of large components.

We create the cutter plotter’s path with a computer program—like we said, it’s digital. Before the machine gets to work, we lay out a sheet with that digitally-created path on top of the table. The blade moves from there, and in the end, you’ll get the product you’re looking for.

What’s better: kiss cut, or die cut?

It really depends on the type of product you’re trying to make. Often, we associate kiss cutting versus die cutting with sticker products. That could be signage stickers or smaller, more complex stickers. While both processes can deliver great results, it’s important to know the pros and cons of each one. That way, you can save time—and often money—by selecting the perfect process.

A die cutter cuts through both the top and bottom layers of the material. When it comes to stickers, that means this process usually suits more complicated designers better than kiss cutting. However, it makes the removal of the top layer a little more complicated, and sometimes more prone to tearing. It leaves you with a clean, professional look, and though it can be more expensive than kiss cutting, it leaves you with less excess material. That means less waste—and ultimately, less money down the drain.

Kiss cutting only cuts the top layer, which leaves the sticker design on a more expansive backing. Think of those sticker sheets you’re probably familiar with—it’s similar to that. These stickers are easier to peel off by hand. However, kiss cutting doesn’t work as well for larger designs.

FAQs: What You Need to Know

Have some questions about flatbed die cutting or contract manufacturing? Luckily, we have answers!

What kinds of materials do we use with flatbed die cutters?

We can process a number of different materials with flatbed die cutting machines. These include:

  • Plastic
  • Metal
  • Foam
  • Fiber
  • Paper
  • Fabric
  • Composites
  • Foil
  • Laminates
  • Rubber
  • And more!

The types of materials we work with really depends on the design of steel rule die and the degree of pressure we use. Usually, we take the type of material we’re working with into account when determining the die’s design.

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

A flatbed die cutter presses the die vertically onto a stationary sheet of material. A rotary die cutter uses a cylindrical die on a rotating drum. It cuts thinner materials at a high volume, while a flatbed die cutter works with thicker materials. Although it can fulfill large orders, it works at a smaller volume compared to a rotary die cutter.

Can third party manufacturers offer custom products?

Yes, an experienced third party manufacturer like CTI can provide customized products. One client of ours wanted to develop peel-and-stick roofing for flat industrial buildings. Not only were we able to do so—we tested and experimented until the client received exactly what they needed.

Whether you’re ready to begin or to simply learn more, the best move is to contact CTI now. Call us at 419-924-5566 or reach out here today!