In materials manufacturing, you’ll hear a lot of talk about different types of dies, die accessories, and rotary die-cutting processes; but what is the die-cutting process exactly? Rotary die cutting is the process of using a die and other specialty tools for converting and fabricating identical shapes for manufacturing for assembly. The majority of consumer goods products companies such as credit card manufacturers, for example, would have several lines of die-cutting presses specifically engineered to cut plastic into wallet-sized rectangles. No matter what the industry is or what is being manufactured, die-cutting requires a high level of precision. At Maxcess, we work with various industries, providing expertly engineered precision cutting solutions to get the job done to your specifications. 

What is a Die?

A die is a machining tool used to cut or form a specific shape into a specific material. Think of a die-cutting system like a cookie cutter that is pressed into a substrate (cookie dough in this case) to create a series of identical shapes. Dies come in two basic types: steel-rule dies (or cookie-cutter dies) and rotary dies like those manufactured and distributed by Maxcess.

What is a Die Cut?

By definition, die cutting is a specialized fabrication process using machines and other tools to convert stock material through cutting, forming, and shearing. Manufactured dies are a piece of metal tooling that cut a specific shape out of the desired material, almost like a cookie cutter. 

Die cuts come in all shapes and sizes depending on the application for which they’re being used. Precision die-cutting is not limited to major manufacturers as many crafters and scrapbookers utilize small die-cutting machines to cut intricate shapes in paper, cardstock, vinyl, and more. When utilized in major manufacturing operations, the machinery is of course substantially larger and more complex, with industrial die cutters designed for fast and precise die-cutting of various substrates. These can be outfitted with one of two types of dies: 

  • Flatbed Dies: Operated by a hydraulic press, the design is pressed into the material. This method is best for low-volume, large-size projects, as well as heavier, thicker materials.
  • Rotary Dies: Rotates and presses the design onto a constantly moving web. Rotary die cutting is best for long runs of material as it maximizes efficiency and production while keeping downtime to a minimum

How Does Die Cutting Work?

In a nutshell, die cutting involves taking a die (rotary or flatbed) and pressing it into the substrate with enough pressure to achieve the desired result. More often than not, the desired result is a clean and crisp cut. Although dies can also be engineered to do embossing, pressing, perforating, or indenting if that’s what the product calls for. A die engineered to produce a cardboard box, for example, would need to cut the shape of the unfolded box as well as apply perforated or indented lines where appropriate.

What Industries Use Die Cutting Systems?

Precision die cutting is used in several manufacturing industries for a wide array of everyday and specialty products. Everything from the clothes you wear to the phone in your pocket to the car you drive to work is likely manufactured in a facility that uses die-cutting. At Maxcess, our dies are specially engineered for the following:

For Help With Die Cutting Services, Work With the Experts

Naturally, we’ve only begun to scratch the surface of what die cutting entails and the types of applications for which it is used. But to summarize, die cutting is a process that makes manufacturing like items much simpler and more efficient. For more information on web guiding systems, die-cutting materials, and other die accessories distributed by Maxcess, browse our online catalog. To discuss ways to improve your die-cutting services, or learn more about custom die-cutting solutions, contact our team today.