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It’s a common misconception that flexible material converters keep die cutting tools on-site, ready to go for your project; we actually use your technical drawings to order a custom-made die cutting tool for each new part.
Many (if not most) of the thousands of part designs that Strouse has worked with over the years have become valuable die cutting tools thanks to the hard work of our suppliers and engineers.
Once you’ve learned more about your tooling cost, you’ll better understand why you’re paying for partial tooling charges.
3 Key Factors that Determine Your Die Cut Tooling Cost
Tools are an essential part of any die cutting process. To create unique products, converters must buy new dies for nearly every project.
Keeping a die cutting tool is like using a car: there will be maintenance along the way—maintenance Strouse usually pays for. Die cutting tools wear out over time and require replacement, cleaning, and storage. Just know that Strouse may not cover retooling costs if you use highly abrasive materials or make significant design changes that necessitate a new tool.
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1. THE INITIAL COST
When you send us your drawing, our engineers make slight alterations to your sketch so the tool cuts more accurately as the material passes through a die cut press. Once we’ve optimized your drawing for production, we forward it to the die cutting tool manufacturer.
2. MATERIAL ABRASIVITY
Cutting sandpaper with scissors causes the blades to dull and erode; similarly, cutting abrasive materials (those with a “hard” or “rough” component or coating) will damage the edges of a die cutting tool. This causes your die cutting tool to erode quickly, leading to more frequent retooling and replacements over time.
Examples of materials that are often abrasive include (but aren’t limited to):
- Ceramics
- Metals
- White inks (titanium dioxide pigment)
- Carbon fiber
- Thicker paper
Abrasive materials reduce the typical die life, but it’s difficult to predict how long each die cutting tool will last before wearing out completely. The life of the tool depends on the material it's cutting, how it's cut, and the press speed. At most, your converter can offer a rough estimate of replacement based on how long it can cut material.
Abrasive materials aren’t the only challenging materials to process; cutting small features in thick materials, such as foam and rubber, can increase the cost of the converting process or the tool.
3. DESIGN CHANGES
The final circumstance in which you could end up having to pay for die cut tooling is if you change your part design (altering the measurements, tolerances, or materials of your part in any way) after purchasing the initial die cutting tool.
Minor alterations or material changes might allow us to continue using the same tool, but we won’t be able to retool to accommodate design modifications for considerable changes. Replacing die cut tools can become expensive, so if you can avoid it, buying multiple dies is ill-advised.
What Else Do I Need to Know About Die Cut Tooling?
Although tooling isn’t the usual project driver for cost, we might be able to try using galvo-laser, flexible die cut tools or pursue other options, like flatbed laser or digital knife cutting methods, which are available as non-tool options for low quantities, depending on the complexity of the materials.
If your project deals with small quantities, you can often avoid tooling altogether. As your converter, Strouse will lay out the tooling cost without trying to hide it within the cost of your die cut part.
If you have any questions or are unsure about the cost of your die cut tooling, reach out to discuss your project today.
Originally published: January 30, 2023
