New technology die cutting
The new technology dies have many similarities with the traditional ones, only the wooden base has been replaced by a thin metal layer allowing the mounting on a magnetic cylinder. The accuracy of the height of the cutting lines is within a few micron thus allowing a fixed gap between the magnetic cylinder and the anvil cylinder. Counter creasing lines can be mounted in the traditional way by using self-adhesive lines, which is as time consuming as the old system. Alternatively it is possible to use double magnetic cylinders with 2 flexible dies. Both dies are registered with pins and holes and are mounted simultaneously. The elimination of adjustments allow make ready times of a few minutes.
The dies are too complex to manufacture in-house and needs to be purchased at a die manufacturer. The process starts with a metal sheet with a photosensitive layer on top. The sheets is exposed with the image and developed afterwards. The exposed sheets is than passing en etching machine were the exposed material is removed until a basic thickness is achieved between 0,15 and 0,2 mm. The sheet with blunt lines is now going to a grinding machine for sharpening the lines. Depending on the application different cutting angles and types of finishing is possible. The cutting angle can vary between 40° and 110°.
Dies are available in different qualities:
- The standard quality is etched and sharpened only. These dies will last up to 300.000 revolutions, a perfect quality for regular use.
- The hardened die is suitable for standard products that are made in high volume, or repeated products, they last 2 to 3 times longer than the standard quality.