Die cutting is one of the main steps in carton forming. With more color printed packaging cartons, die cutting does more than protect the product and make transport easier. It also shapes the carton for product display and shelf appeal. The three main methods are flatbed, cylinder-on-flatbed, and rotary-to-rotary. Each has pros and cons.
Flatbed die cutting
Flatbed die cutting uses a flat die and a flat-edge cutting rule. The blade cuts through the whole corrugated board at once. This gives the highest accuracy among the three methods. It handles adhesive labels, cardstock, corrugated board, and other materials.
Pros:
High cutting accuracy. Works with many materials.
Vertical semi-automatic flatbed machines are simple, easy to maintain, and easy to operate. Die and creasing plate changes are simple.
Horizontal flatbed machines are safe and reliable, with high automation and output. Some have automatic waste stripping.
Cons:
Vertical semi-automatic machines need more operator effort and run at lower output. They are often used for small batches.
Horizontal flatbed machines cost more. They are not suited to very large format die cutting.
Cylinder-on-flatbed die cutting
Cylinder-on-flatbed die cutting uses a cylindrical pressure cylinder instead of a platen. The cutting roller is usually on top, and the die is below. Cutting happens along a line contact. The machine sees lower pressure, even force, and a stable load. It can handle larger formats and materials of different thickness.
Pros:
Even pressure and stable load. Suits different materials and thicknesses.
Lower purchase cost and good safety.
Cons:
Low efficiency. Less used now, but still found in some small carton plants.
Rotary-to-rotary die cutting
The die cylinder rotates continuously at high speed. Output is the highest among die-cutting and creasing machines. Carton accuracy can be held to ±1 mm. The machine is simple to operate, safe, reliable, and has a long service life.
Pros:
High output and high die-cutting accuracy.
Simple operation, safe and reliable, long service life.
Cons:
Purchase cost may be higher than the other two methods. Its efficiency and accuracy often offset this cost.
Summary
Each die-cutting method has pros and cons. The choice depends on production needs, material type, budget, and output requirements. In practice, you can select one method or combine methods to get the best result.
Hansheng Automation machines replacement and custom parts for die-cutting equipment from customer drawings for one-off and small-batch orders.
