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Material Considerations for Rotary Die Cutting

Rotary die cutting works with a wide range of suitable materials that includes paper, plastic, foam, metal, laminates, and fabrics. Knowing what type of web material will be converted helps to determine optimal configurations and rotary die cutting setting— including the design of the rotary die.

Rotary die cutting

Clearance of cutting machines is adjusted to meet the standards of materials based on compressibility and thickness. Clearance is defined as the gap between the anvil and die cutting cylinder. Clearance that is at normal pretension contributes to cutting pressure applied to webs as they run through cutting stations. When clearance is not big enough, it can create excess cutting pressure, heavier die cuts, and machine component fatigue. Clearance that is too large will not make adequate cuts. In many cases, there is not enough pressure to cut through webs.

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The properties of a material also influence factors for designing the rotary die cutting process. Depending on the property, dies require specific beveled angles and the cutting edge geometry. Tough and thick materials require large blade heights at steep angles. Thinner materials have shallower angles and heights. Special, multi-layered materials need dies that have different heights and angles on a singular die. In certain cases, materials may require coating applications or special surface treatments.

Rotary Die Cutting

Material properties are also responsible for determining the type of rotary die cutting used: solid die cutting or flexible die cutting. When speaking with our engineers, we will come up with cutting solutions that best suit your application. Thin materials like paper and film are cut with solid or flexible dies, but tougher materials are converted typically by a solid rotary die.


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