1. Die-Cutting Drawing
A die-cutting drawing is an unfolded layout of the full-page carton after the printing process, and serves as the first critical step in manufacturing the die-cutting plate. During the plate-making stage, if a full-page imposition system is used, the die-cutting diagram can be directly output, ensuring that both the printing and die-cutting plates meet standardized specifications. However, when using manual film imposition, the die-cutting diagram must be drawn based on the actual size of the layout. When creating the die-cutting drawing, the positions of the cutting knife and creasing lines should be clearly marked according to national carton drawing standards. To prevent the die-cutting plate from becoming disordered during the process, large areas of the graphics should be closed, and no more than two cutouts should be made. These connecting parts are referred to as "bridges," with widths typically ranging from 3-6 mm 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, with multi-ply wood being the most widely used. The standard thickness of this material is about 18 mm, offering good durability. There are two main methods for cutting the template: sawing machine cutting and laser cutting.
Sawing machine cutting is currently the primary method for processing die-cutting plates. This technique involves using a narrow blade to cut slits for the die-cutting knife and creasing line. The blade thickness corresponds to the thickness of the knife or crease at each location, with typical sizes ranging from 0.7–2.0 mm in thickness and 1.5–3.0 mm in width. A drill is often attached to the saw, allowing holes to be drilled through the template, which then allows the blade to pass through for cutting.
Laser cutting uses a computer-controlled laser to cut the template material by generating high heat. The entire die-cutting diagram is input into the computer, which then guides the movement of the template relative to the laser head. Laser cutting offers high precision, but several factors can affect the quality, making experience essential for optimal results. One major drawback is the high cost of laser cutting machines, which are usually custom-made by specialized manufacturers.
3. Installing Die-Cutting Knife and Creasing Line
Once the template is cut, the die-cutting knife and creasing line must be installed according to the design. High-quality tools are essential to ensure proper performance. Die-cutting knives are available in soft and hard types. Soft knives have a lower hardness (HRC 35), allowing them to bend into tighter arcs, while hard knives are hardened to HRC 56, providing greater strength. Knives also come in standard and double-edged forms, with double-edged knives recommended for thicker cardboard (over 0.5 mm) due to their ability to reduce surface pressure and provide a sharper cut.
When selecting a knife, attention should be paid to whether the blade is cross-grained or straight-grained. Cross-grained blades are more durable and stable, especially for paper applications. Creasing lines are used to create folds on the die-cutting plate, with common thicknesses of 0.7 mm, 1.42 mm, and 2.13 mm, and heights around 22–23.8 mm. The selection of creasing lines should follow the rule that their thickness exceeds the paper thickness, and their height equals the die-cutting knife height minus the paper thickness and 0.05–0.1 mm.
4. Opening Connection Points
Opening connection points is a necessary step in die-cutting plate production. These small cuts allow the carton and waste edges to remain partially connected, ensuring smooth feeding and receiving during the next steps. Special equipment such as a knife-line punching machine should be used to avoid damaging the knife line or causing burrs. It's important not to open these points where the die-cutting knife crosses a bridge. Common connection point widths include 0.3, 0.4, 0.5, 0.6, 0.8, and 1.0 mm, with 0.4 mm being the most common. These points are typically placed in hidden areas to avoid affecting the final product's appearance.
5. Applying Sponge Tape
After the die-cutting plate is assembled, sponge tape is applied to both sides of the knife line to prevent the knife from sticking to the paper and to ensure smooth operation. The choice of sponge tape depends on the machine's speed and conditions. Different hardness levels—standard, hard, and extra-hard—are available to suit various applications. The ideal distance between the sponge tape and the knife is 1–2 mm, as being too close may cause lateral force and damage the paper, while being too far away reduces its effectiveness.
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 needed. A thin backing paper (0.05 mm thick) is placed under the die-cutting plate to adjust the knife height. If certain blades still don't cut properly, local padding with narrow strips of paper is applied directly to the bottom of the knife to compensate for the height difference. This ensures accurate and consistent cutting results.
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