Die cutting is one of the most dependable methods for creating predetermined shapes from various materials. It provides quick and precise clean cuts, making it ideal for large production runs. The key question is: which machine will help you maximize the potential of die cutting?
The two most popular options are flatbed and rotary die cutting machines. Each has its advantages and disadvantages, which can either benefit or hinder your specific business needs.
Rotary Die Cutting
A rotary die cutter, operated electrically, utilizes a rotating cylindrical die, also known as a die station. The material is fed through the die station, where a rotary tool cuts the sheets into smaller shapes or perforations.
Depending on your machine's specifications, rotary die cutting can produce complex multi-layer custom-cut products. The machine is capable of performing multiple functions within the same processing cycle, including cutting, placing, and laminating materials from start to finish.
The continuous rotation of the machine eliminates wasted or unproductive motion, unlike flatbed die cutters.
A prime example of a rotary die cut product is adhesive bandages, where the rotary die cutter cuts and perforates the plastic while applying the cloth middle and peel-back tabs—all in one processing cycle.
Pros of Rotary Die Cutting
- High-Speed Efficiency: Ideal for high-volume orders due to the machine’s fast cutting speed.
- Precision: Delivers exceptional precision that surpasses flatbed machines, making it suitable for challenging materials.
- Multi-Functionality: Capable of performing multiple functions simultaneously, including printing, perforating, and laminating.
- Kiss Cutting: Allows kiss cutting, which cuts through the main material while leaving the backing paper intact.
Cons of Rotary Die Cutting
- Rotary die cutting is more expensive compared to flatbed because of the cost of machining the die.
- Engraved dies are also expensive to purchase and maintain.
- It requires larger production runs to justify the costs associated with tooling and set-up.
- It doesn’t work well for thicker, denser materials.
- Also, the material has to be on a roller so that it feeds into the machine continuously. This means you can’t use materials that only come in sheets.
Flatbed Rotary 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.
A flatbed die cutter operates hydraulically and utilizes a steel rule die shaped to match the desired cut. During the machine's cycling process, hydraulic pressure drives downward through the material to punch out the die-cut parts. This vertical motion can sometimes cause slight curvature on the edges of the finished products, but proper techniques can help mitigate this issue.
Pros of Flatbed Die Cutting
- Thicker Material Capability: Can cut through much thicker, denser materials due to the machine's wider opening.
- Cost-Effective: More affordable than rotary die cutting, with lower tooling and machine costs.
- Efficient Material Use: Allows for closer grouping of parts on the sheet, reducing scrap and waste.
- Versatile Material Compatibility: Works well with a wider variety of materials, whether thick or thin, and available in sheets or rolls.
Cons of Flatbed Die Cutting
- Slower Production Rate: The primary downside is its slower production speed, which may be problematic for high-volume needs.
- Lack of Multi-Functionality: Unlike rotary die cutting, it doesn’t offer multi-function features such as printing, perforating, and laminating.
- Longer Setup Time: Takes more time to set up due to the use of steel rule dies.
- Precision Limitations: While cuts are clean and accurate, flatbed die cutting does not match the precision level of rotary die cutting.
The Advantages of Each Die-Cutting Method
Each die-cutting method has its own advantages, with the most efficient choice depending on the specific needs of the project.
1. Flatbed Die Cutting – Simple Yet Effective
Flatbed die cutting is one of the most straightforward methods, making it a popular choice for many projects. In this method, a cutting die is placed in a hydraulic press, which stamps out shapes similar to a cookie cutter. This technique is ideal for cutting thick materials or materials in sheet form. The tools can be swapped out easily and quickly, making flatbed die cutting especially suitable for low-volume production or when a product isn’t performing well with rotary or laser cutting methods.
2. Rotary Die Cutting – Ideal for High-Volume Production
Rotary die cutting takes the concept of flatbed cutting and adapts it for high-volume operations by wrapping the cutting die around a rotating cylinder. This method allows multiple shapes to be cut continuously from rolls of material, making it perfect for large-scale production. The rotating cylinder blade ensures precise cuts to exact lengths while maintaining tight tolerances through servo motors that keep the registration consistent. Known for their durability, rotary dies are particularly advantageous for industries like medical, military, and aerospace, where high precision and material consistency are critical.
Questions to Consider When Choosing
When deciding between a flatbed and a rotary die cut machine, consider the following questions to identify the best fit for your production needs:
How thick is the material? Both rotary and flatbed die cutting can handle thin materials, but if you’re working with materials thicker than 1/8 inch, a flatbed die cutter is the better choice.
What are your volume and speed requirements? For high-volume orders that demand fast turnaround times, rotary die cutting may be the ideal option. Conversely, a flatbed die cutter is typically sufficient for smaller operations.
