Technology Sharing: Six Steps of Die-cutting Production Process

1. Die-Cutting Drawing

A die-cutting drawing is an unfolded layout of a full-page carton after the printing process and serves as the first critical step in producing die-cutting plates. During the plate-making process, if a full-page imposition system is used, the die-cutting diagram can be directly output, ensuring consistency between the printing and die-cutting plates. If manual film imposition is applied, the die-cutting diagram must be drawn based on the actual layout size during the die-cutting plate production. When creating the die-cutting drawing, the positions of the cutting knife and creasing lines should be clearly marked according to national standards for carton drawings. To prevent the die-cutting plate from becoming disordered during the process, large areas of the graphics should be closed, with no more than two cutouts. These are known as "bridges," typically designed to be 3–6 mm wide for smaller versions and 8–9 mm for larger ones.

2. Die-Cutting Template

The materials commonly used for die-cutting templates include multi-ply wood, high-density board, and bakelite. Multi-ply wood is widely used today due to its durability and stability, with a typical thickness of about 18 mm. There are two main types of die-cutting templates: those made using a sawing machine and those produced through laser cutting.

Sawing machine cutting is currently the primary method for processing die-cutting templates. This involves using a thin blade to cut narrow slits along the die-cutting line and crease line. The blade thickness matches the width of the knife or crease line, typically ranging from 0.7 to 2.0 mm in thickness and 1.5 to 3.0 mm in width. The saw is often equipped with a drill that allows for hole drilling on the template. After drilling, the blade can pass through the hole to complete the cut.

Laser cutting, on the other hand, uses computer-controlled machines that utilize high-temperature lasers to cut the material. The die-cutting diagram is input into the computer, which then controls the movement of the template relative to the laser head. Laser cutting offers high precision, but factors such as material type and laser settings can affect the final quality. Experience plays a key role in achieving the best results. However, laser cutting machines are expensive and usually custom-made by specialized manufacturers.

3. Installing Die-Cutting Knives and Creasing Lines

Once the template is cut, the die-cutting knives and creasing lines must be installed according to the design layout. High-quality tools are essential to ensure accurate and consistent results. Die-cutting knives come in different types, including soft and hard knives. Soft knives have a lower hardness (HRC 35) and allow for tighter bends, while hard knives (HRC 56) are stiffer and more durable.

Knives also vary in shape, such as standard and double-edged knives. For thicker cardboard (over 0.5 mm), double-edged knives are recommended, as they reduce the risk of tearing and provide a sharper cut. When selecting knives, attention should be given to the grain direction of the blade—cross-grained knives offer better performance and longevity when cutting paper.

Creasing lines are used to create fold marks on the die-cutting plate. Common thicknesses are 0.7 mm, 1.42 mm, and 2.13 mm, with heights typically around 22–23.8 mm. The selection of creasing lines should consider the paper thickness, with the line thickness slightly greater than the paper and the height adjusted accordingly.

4. Opening Connection Points

Opening connection points is an essential step in die-cutting plate production. It involves making small cuts along the edge of the die-cutting knife to keep parts of the cardstock connected, ensuring smooth feeding and handling during the next steps. Special equipment like a knife-line punching machine should be used to avoid damaging the knife lines or causing burrs. Connection points are usually placed in hidden areas, with widths ranging from 0.3 to 1.0 mm, with 0.4 mm being the most common. The goal is to minimize visibility and maintain the appearance of the final product.

5. Applying Sponge Tape

After installing the die-cutting knives and creasing lines, sponge tape is applied to both sides of the knife lines to prevent the paper from sticking during the cutting process. This helps the paper move smoothly and improves the overall cutting efficiency. The choice of sponge tape depends on the machine speed, the size of the die-cutting area, and other conditions. Different types of tapes, such as standard, hard, and extra-hard, are available depending on the application. The ideal distance between the sponge tape and the knife line is 1–2 mm to avoid damage or ineffective adhesion.

6. Trial Cutting and Padding

Once the die-cutting plate is completed, it must be tested on the die-cutting machine. If some areas are not fully cut, padding is applied locally. A backing sheet of 0.05 mm thickness is placed under the die-cutting plate to adjust the knife height. If certain blades still fail to cut, a position pad is added directly beneath the knife using narrow strips of padding paper. This ensures proper alignment and optimal cutting performance.

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