Rotary die cutting is a fast and efficient manufacturing process used to cut flat materials into precise shapes. There are two types of rotary die cutting: metal-to-metal cutting and kiss cutting. The process involves a rolling cylinder die and a conveyor belt to feed the material. It is commonly used for mass production of cardboard packaging and adhesive-backed products. Multi-height engraved dies can combine both types of cuts in one operation.
Rotary die cutting is a manufacturing process used to cut a design out of a flat material. This method is commonly used in mass production because it is the most time-efficient method of die-cutting. When an engraved die rolls over the stock material, it cuts through the material leaving pieces that are cut according to the exact pattern engraved on the die. There are two types of rotary die cutting: metal-to-metal cutting and kiss cutting.
In this industrial die-cutting process, the rolling cylinder die is placed in a fixed position at one end of the die-cutting machine, also called a rotary press. The stock material is fed to the engraved die by means of a conveyor belt or other system which moves the material at speed even with the movement of the cylindrical rolling die. When it reaches the appropriate point, the etched die presses and cuts the material.
The pressure of the laminating die, combined with the sharp edges of the etched pattern, allows the rotary die to completely cut through the raw material for metal-to-metal cuts. The stock material is cleanly cut into individual pieces ready for assembly. This form of rotary die-cutting is commonly used to make cardboard packaging or other mass-produced flat parts.
In some cases, it may be preferable to cut only a portion of the stock material. In this type of rotary die cutting, called kiss cutting, the die blades are positioned slightly higher so that the cut cuts through the raw material but not the underlying support material. This type of rotary die-cutting is commonly used for adhesive-backed products, including postage stamps and mailing labels.
Rotary die cutting can also combine both types of cuts in one operation. By creating a multi-height engraved die, the press can be used to cut a number of parts on each sheet. The individual parts that make up the sheet are kiss-cut while the sheet, as a whole, is made by metal-on-metal cutting. This is another form of rotary die-cutting that is popular for sticky-backed items, such as rolls of stickers or sheets of printable name tags.
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