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Benefits of using a rotary die cutter


Manufacturing Services & Engineering

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An advanced rotary die cutting machine is capable of executing far more than just simple cuts. It can form and assemble complex final products, with multiple joined components and finishing treatments, all in a single run.

What’s more, a rotary die cutter can apply these processes to an incredibly broad range of materials and component types. It’s difficult to find a more versatile and efficient fabrication method, particularly one that can deliver with the same winning combination of speed and accuracy.

To illustrate the full potential a rotary die cutter has to offer, we’ve chosen its top 7 capabilities and features. They are:

  1. Vast material selection
  2. Lamination
  3. Part complexity
  4. Kiss cutting
  5. Island placement
  6. Perforation
  7. Single or multiple release tabs

We think this list gets at the heart of what makes rotary die cutting so appealing and effective. Read on to learn more!

1. Vast material selection

Rotary die cutting is a profoundly flexible technique when it comes to materials. So long as the material is available in a web that can be fed off of a spool, it can almost certainly be converted using this method.

Common parent materials include:

• Elastomers and rubber materials
• Natural textiles
• Synthetic textiles
• Paper and cardboard
• Plastics
• Composite materials
• Thin metals

2. Lamination

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The addition of an adhesive is one of the most popular lamination processes for our clients. We can easily add a pressure-sensitive adhesive to one or both sides of a component, then finish with a release liner to protect the component until it’s ready to be applied during assembly.

An advanced rotary die cutter is capable of not only cutting, but a variety of finishing steps including lamination. The strength, stability, appearance, sound insulation and shelf life of a material can all be improved through lamination with different substances.

The advanced tension controls on our rotary allow for laminating thin materials without distortion to the material or the final part.


3. Part complexity

Rotary die cutting is absolutely the fastest way to produce feature-dense 2D designs. When an order entails large volumes or expedited timing, there’s still no need to sacrifice on detail and accuracy with this technique.

4. Kiss cutting

When a laminated material needs to be cut in such a way that the release liner remains intact, that’s called kiss cutting. Slicing to a specified depth while preserving the material below is a precision endeavor, and particularly desirable for sheets of adhesive-backed components. These components can then be efficiently distributed, separated and placed on your assembly lines.

5. Island placement

Another finishing step an advanced rotary die cutter can take care of automatically is island placement. This is when a secondary component is placed within a specified adhesive zone on a larger part to create the final design.

An example of a common usage for island placement is medical bandages. For these designs, an absorbent pad is placed on a larger, adhesive-backed fabric strip. Then a release liner is applied to complete the design.

6. Perforations and creases

The dies used in a rotary die cutter can be made with different types of blades. Instead of a slicing blade intended to cut cleanly through a material, a perforating blade can be used to create perforated lines, or a creasing blade to create creases.

These design features increase the ease of bending or tearing components in a specified way. They’re particularly useful for assembly lines and for facilitating an easier user experience.

7. Single or multiple release tabs

These mechanisms are used to facilitate easy removal of the liner from an adhesive-coated component. These aids increase efficiency during assembly, minimizing time spent removing backing material and the number of components wasted due to damage during the removal process.

Reap the benefits of rotary die cutting with Sur-Seal

No matter the size or complexity of your design, the Sur-Seal® company has a die-cutting operation suited to your needs. Our advanced rotary machines can handle all of the features we’ve discussed above and more, all with fast and precise results. If you have any questions or are interested in working with us, please don’t hesitate to get in touch or request a quote today!

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