What is Rotary Die Cutting? Problems it Solves and Uses

Can you cut out the same shape twice in a row? How about a million times? 

Rotary die cutting is a manufacturing method that produces large quantities of parts made out of flexible materials. So, if you needed to go from two parts to a million, it would be a great place to look.

Over the past 38 years, Strouse has used rotary die cutting to rapidly produce large quantities of sophisticated parts for healthcare, aerospace, and other industries. If you’re looking for an efficient production method, keep reading to learn about rotary die cutting—including what it is, how it works, and how it benefits you regardless of your product or industry.

THE DIE CUTTING BASICS

A die is a tool used to cut material into a given shape. Die tools, which are often custom-built from metal, cut through surfaces like paper, fabric, adhesive, and foam to create the desired shape. This allows companies to make identically sized and shaped cuts of cloth or plastic.

Shoemakers in the 19th century used die tools to cut identical shoe shapes from leather sheets. Now, manufacturers use modern die cutting machines that rapidly slice through different materials to produce multilayered or otherwise complex parts.

What Is Rotary Die Cutting?

As you may know, rotary motion refers to a circular movement around a singular turning point. Rotary die cutting uses a cylindrical die to cut shapes out of material. The die moves in a circular motion and uses blades to cut out the desired shape around the entirety of the tool. 

The die cutting process is incredibly efficient because it cuts out multiple identical shapes as it rotates. Rotary die cutting is ideal for engineering industries where metal, plastic, or adhesive components must be precisely the same size for equipment to work. 

In terms of equipment, die cut press machines tend to require many minor adjustments before they’re ready to run, which can lead to longer setup times. After setup, an operator is in charge of restocking the rotary machine's material when needed, measuring samples, and monitoring the run progress. 

ROTARY VS FLATBED VS LASER DIE CUTTING

Rotary die cutting is different from flatbed or laser die cutting. 

FLAT BED DIE CUTTING 

While the rotary process uses a cylinder die tool to cut shapes out of a material, flat bed die cutting uses a hydraulic flat bed press to cut the desired shape.

Flat bed die cutting is suitable for low-volume projects, yet inefficient for high-volume ones, whereas rotary die cutting machines are often a lot more efficient at making high volume products.

LASER CUTTING

Laser cutting differs entirely from flatbed and rotary die cutting: rather than steel, it uses a laser to create the desired shape. 

The light from the laser sears into the materials and produces a variety of shapes. While laser die cutting is efficient for some materials, others react poorly to the light and may be destroyed.

Different projects benefit from using particular cutting methods, so your converter will likely suggest a type that suits your unique design. 

When Do You Use Rotary Die Cutting?

From simple die cut shapes to complex, multi-layer products, die cutting helps increase speed and consistency in many industries. 

Here are a few specific uses and instances of rotary die cutting.

CREATIVE PURSUITS

• • Logos
  • Labels
  • Surface protectors

MEDICAL DEVICES & WOUND CARE

• • Medical adhesive tape
  • Wound dressings
  • Stick to skin adhesives
  • Device components 

AUTOMOTIVE 

• • Protective films
  • Masking tapes
  • Seals and gaskets
  • Cell-to-cell EV battery bonding 

ELECTRONICS

• • Thermal management
  • EMI gaskets 
  • Screen protection
  • Insulation

& many more applications. 

What Materials Can You Rotary Die Cut? 

Rotary die cutting can cut a wide variety of materials, so wide in fact, it’d be challenging to name all the flexible materials we can die cut. 

Many converters provide die cutting services for flexible materials, including pressure-sensitive adhesive tapes, foils, fabrics, and numerous others. While converters CAN cut most flexible materials, achieving tight die cut tolerances on elastic, abrasive, thick, or unsupported materials is more challenging (and expensive). 

What Are the Benefits of Rotary Die Cutting Methods? 

Now that you know what rotary die cuts are, why pursue them?

COST EFFECTIVE 

Die cut parts can be extremely cost-effective at high volumes and often have a decent turnaround time if projects are planned far enough in advance. 

BETTER PART CONSISTENCY

Die cutting is far more accurate and repeatable than manual processes. Plus, rotary machines can combine different steps, such as die cutting, adhesive laminating, perforating, and more, into one seamless, scalable process. 

The Downsides to Rotary Die Cutting

The custom die cutting process isn’t for every project, so it’s only fair that we discuss the reasons why it may not suit certain applications. 

CUSTOM TOOLING 

Die cutting often requires the upfront purchase of custom tooling, which involves paying the initial cost and waiting for the tool to be fabricated. 

POTENTIAL TOLERANCE LIMITATIONS

Depending on your chosen material and design, it’s possible that your tolerances might be too tight for rotary die cutting. Machine shop tolerances don’t always translate to rotary processes, which is why you’ll want to consult with a converter before you lock in your final design.

MINIMUM ORDER QUANTITIES FOR MATERIALS

Large material roll purchases require MOQs, which can increase your initial cost. However, if you plan on ordering higher quantities or scaling up your process, larger orders will have a lower price per part.

What Are My Die Cutting Options?

If you’re looking for identical components, rotary die cutting has multiple options. 

i. PURCHASING A MACHINE

Purchasing a machine will give you more control over your production process. However, if you’re planning to purchase a machine, make sure your business has the capacity to pay the upfront costs (which can range from a few hundred thousand to a few million dollars) and train operators and engineers to navigate the complexities of the die cutting process. 

ii. DIE CUTTING SERVICES

Not every company is equipped to become die cutting experts, which is why you may want to use a trustworthy partner. Before you reach out, evaluate where you are in the process:

Are you still planning a concept? Or have you already found material, built a design, and are seeking out prototypes? Product development isn’t always linear, but you’ll want to have some sort of drawing with measurements and an idea about the material before approaching an adhesive converter. 

If you’re ready to build your product, then look no further for rotary die cutting services—contact Strouse to start your die cutting project today. Our team will walk you through the steps to building the most efficient process for your intended purpose.

Got any questions? Reach out or learn more about rotary die cutting in our Learning Center. 

 

 

Originally published: January 6, 2020