Die-cutting lies at the heart of manufacturing, and the Sur-Seal® Company has the techniques and expertise to deliver exceptional die-cut products. Whether you need high precision, rapid turnaround, cost-effective strategies or all of the above, Sur-Seal can help.

The methods we use are:

While not technically die cutting, Sur-Seal also offers other methods of cutting such as water jet, knife and CNC routing. In this article, we will explore CNC Routing as a comparison to rotary and flat-bed die-cutting.

Have confidence that your product will be cut right, every time, with this flexible range of techniques at our disposal.

All About the Die-Cutting Techniques Used by Sur-Seal

Rotary Die-Cutting

Rotary die-cutting separates itself from standard die-cutting operations by enabling rapid, large-scale production with high accuracy. Raw material can be processed at speeds up to 300 feet per minute.

The process begins with a continuous roll of parent material, known as a web. This web is continuously fed into a set of cylindrical dies which rotate in-line with one another. This continuous cycling capability enables pressing, cutting, shearing and joining in one process, on one machine.

Considerations for rotary die-cutting

  • One machine takes raw material to finished product, reducing downtime and increasing throughput.
  • Thin materials can be processed very quickly.

Flatbed die-cutting uses steel dies and hydraulic or electric pressure to cut components from stock material.

In this technique, the raw stock material is pulled through a set of rollers and fed across the cutting surface. Once the material has been pulled to a specific length, the hydraulic head presses the die into the material to form the component.

After the cut has been executed, the machine moves the finished component away from the cutting surface while simultaneously pulling new material in. This process repeats until the desired quantity is obtained.

Considerations for flatbed die-cutting

  • Lower tool costs and slower speed than rotary die-cutting for simple parts.
  • Best suited for
    • Most general applications
    • Low-volume orders
  • Male/female or matched metal tools can be used for complex flatbed cutting components.

CNC routing uses a servo-driven cutting head. This cutting head is:

  • Accurate up to 1/100th of a millimeter (material dependent)
  • Operated on 3 numerical control axes (X,Y and Z)

The machine operator programs the CNC equipment with your design parameters. Then the machine head moves along a defined plane, cutting the material to your exact specifications.

Considerations for CNC routing

  • No hydraulic action means less energy is required.
  • Mobility of the cutting head increases total raw material yield.
  • Singular cutting head means the cutting process can take much longer than alternative methods.