Technologies We Use for Custom Rotary Die Design
ICD integrates proven design principles, sensor readiness, and materials engineering to produce high-precision dies built for your exact application.
Anti-Bounce Design Principles (US 11,292,146 B2)
Places pressure cylinders optimally to minimize bounce at speed and ensure consistent cut depth.
Laser-Driven Bounce Detection Integration
Designs are sensor-ready and validated with bounce data to protect blades and maintain precision.
Engineered Edge Materials for Durability
We specify tungsten-carbide, powdered-metal, or other edge materials matched to your web, abrasiveness, and run speeds.
Let us design a smarter die that lasts longer, runs cleaner, and adapts to your bonding or lamination processes.
Custom Rotary Die Designed for Precision & Performance
Using in-house CAD and FEA modeling, we simulate the entire cylinder’s deflection to ensure your die ships ready to run, not requiring re-shimming. Each edge is ground to ±0.0001 in., then checked on our optical comparator before assembly.
No two applications are the same. We design dies to fit your exact product specs, line speeds and operational constraints, whether you’re handling intricate label shapes or wide-format flexible films.
We source and recommend the right die steel, coatings, and wear-resistant materials based on your converting process and the abrasiveness of the substrates involved.
Our engineers leverage ICD’s legacy of precision to deliver dies with ultra-tight tolerances and edge profiles optimized for your specific material, thereby reducing waste, improving cut quality, and enhancing line efficiency.
Design Capabilities & Specifications
Maxcess and ICD offer unmatched flexibility in die construction, tailored to your unique converting line:
| Capability | Spec (US / Metric) |
|---|---|
| Roll Diameter | Up to 26″ / 660 mm |
| Pattern Width | Up to 50″ / 1 270 mm |
| Overall Die Length | Up to 125″ / 3 175 mm |
| Die Materials | Tungsten-Carbide, Powdered-Metal, Tool Steel |
| Bonding Support | Ultrasonic, Thermal, Pressure, Elastic Entrapment |
| Tolerances | Ultra-tight, material-specific edge profiles |
Applications We Support
Whether you’re launching a new product or fine-tuning a complex converting line, we design dies for a wide range of industries or materials.
Flexible Packaging
High-speed dies engineered for thin films, laminates, and multi-layer substrates.
Nonwovens
Custom solutions that deliver clean, consistent cuts for hygiene, medical, and filtration projects.
Specialty Labels
We support custom die needs for prime and functional labels, from micro-perforations to unique contour cuts.
Foam, Film & Foil Processing
Robust dies are designed to handle compression, static buildup, and complex material stacks without sacrificing accuracy.
Automotive Films
Laminates, sound-dampening pads, wire-harness tapes.
Electronic Tapes
EMI/RFI shielding, thermal interface pads, optical films.
Supported Tooling Configurations
Our custom die design services extend to all common rotary die types and machine configurations, including:
- Window Dies
- Patch Gummers
- Profile, Separating, or Patch Knives
- Tape Cylinders
- Score Shafts
- Gears & Coupling
- Bearing Blocks
- Custom Converting Components
Not sure which material fits your run volume?
Our Design Process
We combine hands-on engineering consultation with cutting-edge modeling and prototyping to ensure the die you get is exactly what you need.
Consultation & Feasibility
We start by understanding your material stack, tolerances, product specs, and line setup. This allows us to assess feasibility and recommend the most effective die architecture.
CAD Modeling & Prototyping
Our team creates detailed CAD models and can provide physical prototypes or test cuts upon request, reducing development risk and ensuring performance before production.
Final Design & Fabrication
Once approved, your custom die is precision-manufactured using ICD’s proven fabrication techniques, backed by Maxcess’s service and support infrastructure.
Additional ICD Services
Pair your die design with services that validate performance, implement upgrades, and certify compliance
Die Rebuilding & Repair
Restore edge geometry and extend die life; apply bounce‑reducing upgrades where appropriate.
Die Quality Assurance
Inspection, measurement, and documentation to verify specs and meet regulatory/customer requirements.
Die Product Evaluation
Diagnose wear, misalignment, and performance risks before they impact yield.
Already Using a Die? We Can Reverse Engineer It
If you’re looking to improve or replace an existing die, we offer complete evaluation and reverse engineering services to replicate, enhance, or reimagine your current tooling with more innovative design and better materials. Want to upgrade during the redesign? We can spec ICD anti-bounce or bonding-friendly die features into your new tooling.
ICD’s Legacy of Design Excellence
With over 40 years of rotary die innovation, International Cutting Die has earned its place as a trusted partner in precision converting. Now as part of Maxcess, ICD’s custom dies continue to set the industry benchmark for quality, longevity, and support.
Why Choose ICD-Engineered Dies?
- Price: Competitive design-to-value ratio
- Quality: Precision materials and proven performance
- Service: Expert consultation, support, and turnaround
Contact International Cutting Die
Let’s Design Your Next Advantage
Your converting line deserves more than a standard die. Let’s build a better solution together, engineered to solve real problems and deliver measurable performance.