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Die-cutting is a process of using tools to cut materials of low strength like rubber, fibers, foil, fabric, paper, corrugated fibrous plates, cardboard, plastic, adhesive tapes sensitive on the pressure, foam, and tin. Cutting foam is an effective way to produce foam objects of customized sizes in large quantities for different industries. The material you use can influence the type of blades which you will need. Foam die-cutting is a great way to customize your packaging, promotional materials, and other items. In addition to being very cost-effective, this technique allows you to customize the highest quality. It is ideal for mass production as well as individual works. SSA Pana works with EPDM rubber (which is self-adhesive), PE sponge (which can be bonded with heat glue or double-sided tape) and PUR foam (which requires heat sealing).
Die-cutting is a production process of cutting or perforating materials using a specifically shaped tool called a die. A die consists of two metal plates and a hydraulic cylinder between them. The external side of the die has an engraved shape for cutting, as well as holes into which other tools can be incorporated for special purposes like printing or imprinting.
Die-cutting is a tool designed for cutting material with high precision. It uses many tools such as punches, knives or a laser that can be used in the manufacturing of your product. The main reason to use die-cutting is the production of an endless stream of identical components per low prices, without any secondary working operations.
A die-cutting press works in the same way as any other mechanical press. It’s basically just a super-powered version of scissors which instead of blades have sharp pins called punches. The punches hold together two plates called dies that come apart when the machine is activated. That allows us to create shapes in materials using either sharp needles or blades attached vertically to them (to make perforated holes), or horizontally (to make cuts).
The material to be cut passes through the cutting unit on the roller belt. As it enters the cutting area, the material is drawn into the lower part of the die by suction. A steel cutting element then presses against the back of the sheet to hold it in place, while a hydraulic chamber applies pressure to both sides of the mold through a moving piston. This action causes frictional heat that cuts or punches out small pieces at a time until all the pieces are separated from the rest of the material.
The material will move through the die (which is the fixed part) as the punch moves up and down (push/pull out of it). The shape will be die-cut into the second sheet of material that must be underneath it. If only one operation is required to make the shape, there is no need for additional tools, but if two (or more) operations are required, they will be performed by changing the tools accordingly.
The die-cut machine starts with a stationary lower block called a bed that contains mounting points for the die heads and a motor gear assembly that moves up and down due to hydraulic pressure. Next comes the upper frame unit, which contains the paths (horizontal bars that support the upper die) and the guide (a vertical bar that controls the height of the shocks). Next, there is the hydraulic drive that is rotated by an electric or air motor. It transmits power from the outside to the inside via a hydraulic pump. Next in line is the locking mechanism for changing the die head with a quick release, followed by the test stand for quality control.
It’s important to have suitable die-cutting tools, because it can affect the quality of the finished products. Many companies use the universal tool that has rough edges, which can affect the quality of the finished products, but there are companies that offer specially designed tools for specific jobs that will greatly reduce those problems. Such specially designed tools are made possible by using CAD/CAM technology in production, providing a considerable flexibility to die-cutting companies to expand their services for specific requirements.
Cutting can be used for the production of many different shapes, designs, and size for a number of industries, including automotive, textile, electronic, medical, household appliances and packaging food and toys, among other things. Die-cut products have a tall visual appearance with clean lines that create aesthetic attractiveness. Cutting is a cost-effective method that can be used to create large amounts of products at one time.
The advantages of die-cutting include:
Die cutting foam can be done using recycled foam or new foam. The material is also available in different thicknesses, depending on the need. Cutting machines are the easiest way to achieve reliable results, especially for longer product runs or a large number of custom items.
SSA Pana is proud to say that it negotiates the final product with clients down to the smallest details. We are at your disposal for all information and agreements about die-cutting! Call us and make sure of our team’s expertise!
The production plant of SSA Pane is richer for two new die-cut machines. The Atom die-cut machine is used for die-cutting items in contour forms and can exert a 60-ton pressure. It is a highly advanced piece of technology. A kiss-cut machine is a special machine that cuts countless items on the self-adhesive tape, and not individual articles like on the previously described die-cut machines.
