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Flatbed Die Cutting Vs Rotary Die Cutting, Which Suits Your Needs?

Oct 25 , 2024

When it comes to die cutting materials, whether with or without pressure-sensitive adhesive (PSA), two of the most commonly used methods are flatbed and rotary die cutting. Choosing the right method for producing your die cut parts can make all the difference in achieving success or missing out on new business opportunities.

 

Both flatbed and rotary die cutting machines have their own distinct advantages, and in some cases, disadvantages. Understanding these differences will help you determine the best approach for your specific project needs.

 

Let’s take a closer look at each type of machine, starting with flatbed die cutting presses followed by rotary die cutting machines:

 

flatbed die cutter


Flatbed Die Cutting

 

A flatbed die cutting press is a hydraulically operated machine which uses a steel rule die to “click cut” or punch out die cut parts by driving the die in a downward motion through the material.

 

Advantages of Flatbed Die Cutting:

 

- Lower tooling costs: Steel rule dies used in flatbed die cutting are often less expensive than rotary dies.

- Cuts thicker materials: Flatbed machines can handle denser, thicker materials more effectively.

- Reduced material waste: The ability to closely group or nest parts minimizes waste and scrap.

 

Disadvantages of Flatbed Die Cutting:

 

- Slower production speed: Flatbed die cutting typically has a slower output rate compared to rotary die cutting.

- Longer setup times: The setup process takes more time than with rotary machines.

- Limited functionality: Flatbed die cutting cannot perform additional processes like printing, perforating, or laminating.

 

Rotary Die Cutting

 

A rotary die cutting machine operates electrically and uses a rotating cylindrical die to process materials. The material is fed through a die station, where the rotary tool cuts it into smaller parts, shapes, or perforations. This continuous process makes rotary die cutting highly efficient, especially for high-volume production.

 

Advantages of Rotary Die Cutting:


- Higher production rates, allowing for a significantly greater number of parts or pieces to be produced per cycle.

- Superior precision and accuracy, ensuring high-quality die-cut parts.

- Versatility in performing multiple functions such as printing, perforating, and laminating.

 

Disadvantages of Rotary Die Cutting:


- Engraved dies are costly to purchase and maintain.

- Larger production runs are necessary to justify the expenses associated with setup and tooling.

- Less suitable for cutting thicker, denser materials.

 

A rotary die already has the shape set and can quickly repeat that cut repeatedly. Flat bed has to index (start and stop) each time it wants to make a cut. Cutting the same shape across many pieces of material can be challenging, especially if the material is thick.

 

The decision between flatbed and rotary die cutting ultimately depends on the specific needs of each project, including factors such as the material to be cut, the project’s production volume, and the long-term business objectives. Each method has its strengths, and choosing the right one can significantly impact efficiency, cost, and overall success.

flatbed die cutter

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