For material converters like KLINGER IGI, die cutting involves use of a variety of hydraulic presses in multiple platen sizes and tonnages.
These presses perform high speed flatbed die-cutting, high speed rotary die-cutting, automated flatbed (full beam and traveling head) die-cutting, and manual flatbed (full beam and traveling head) die-cutting. The cutting processes we employ in our die cutting services is determined by the size and geometric complexity of the part to be fabricated, the physical characteristics of the material to be cut, the desired edge quality of the part, and of course the volume of parts to be produced.
High Speed Die Cutting processes are often used to produce accurately cut parts with the focus on intricate shapes and kiss cutting.
Since the depth of cut can be controlled precisely between the cylindrical anvil and a precision machined die, this process is ideal for “kiss-cutting” or when zero-gap tolerances are required. Dies are machined from a single piece of tool steel creating a consistently accurate die-cut shape and depth. Material is fed in roll form at high speeds, increasing efficiency while decreasing part price. The process also incorporates multiple in-line processing, making it the efficient and economical solution for medium to high volume runs.
Travel head, full beam, and swing arm presses are also used for Flat Sheet Cutting using Steel Rule Dies.
Flatbed die cutting offers a cost-effective way of making complex two-dimensional shapes in flat materials. And for that reason, they are a cornerstone of our die cutting services capabilities. The cutting die consists of thin strips of steel that is bent into the outlines of the desired part shapes, and then secured into grooves cut into the rigid die base. The steel rule die then is held face down over the material to be cut, or mounted face down in a beam or travel head press (again over the material). Once the machine operator engages the press, the die is forced down into the material to a controllable depth, and the steel edges precisely cut the desired shapes.
This type of die-cutting is perfect for fast turnaround on prototypes and/or production volume runs. It is commonly used to process parts of all sizes as long as exterior and interior features are not overly intricate. KLINGER IGI's steel rule die cutting process will give your parts superior edge quality and a smooth, clean surface cut to very tight and repeatable tolerances, making it the most economical solution for low to medium volume runs. Note, however, that some of this parts production is often performed by CNC waterjets, flash cutting machinery or multi-axis routers to avoid the expense of dies and balance the cost of a part’s piece price with the volume expected to be produced.