Home > contract manufacturing > Superior Solutions for An Industrial Die Cutting Machine
Superior Solutions for An Industrial Die Cutting Machine
If you are looking for an industrial die cutting machine for your business, you likely have many questions. Fortunately, the team at Conversion Technologies International has heard many of them and we have answers.
First, let’s explore some common questions about the die cutting process in general. Then, we’ll go over the different types of die cutting equipment. Finally, we’ll explain how CTI can help you find the best industrial die cutting solutions.
Common Die Cutting Questions
Which industries use die cutting machines?
Likely, more industries than you imagine use die cutting services. Think of all the pieces and parts that go into everyday products that you use. Often, we recognize that paper or cardboard packages must be die cut for final use. Or, it’s common to utilize die cutting for fabrics. Many other materials need shaping as well such as:
CTI has experience in all of the above materials and more. If you have a material that isn’t on the list, don’t worry. We thrive on a challenge and would love to speak with you about our diverse techniques and solutions. Literally, we love to think outside the box!
How do die cutting systems work?
The most basic answer to that question is that you cut parts into shapes with specialized machinery. Depending on the material that you’re using and the custom shape that you need, you affix dies to the machinery that mimic that shape. Clearly, the desired shape of your final product and the material you’re cutting also deems which overall process you need.
Should I purchase my own cutting press?
This answer is a little more complicated. Ultimately, you need to think about not just the cost of the machine but the peripheral tasks that accompany this purchase as well. Manpower, training, and maintenance are just a few of your considerations. Precision cutting not only takes time to learn, it comes with risks. It is imperative that whoever runs your machine has the proper training. The safety of your employees is crucial. Likewise, making sure you have the proper insurance to allow employees to use dangerous equipment is a must.
Additionally, many of these machines take up a large amount of space. Therefore, you must also consider if your business has it. Real estate is expensive. Sometimes, it makes more sense to use someone else’s space so that you don’t have to pay for it directly. At CTI, we have extensive die cutting capabilities. We already have the space and the machinery set up and ready to go!
How long do die cutting services take?
Obviously, this depends on the scope of each individual project. However, our team at CTI has a well-practiced process of providing our customers with the most efficient turnaround possible. Below, we’ll go into that in more detail. Keep in mind, we never sacrifice quality to provide quick turnaround. After all, a product that doesn’t satisfy you or customers is a product that shouldn’t go to market.
That said, our years of experience ensures that we produce quality cut material in a timely manner. No matter the scope and size of your project, we will diligently work with you and your timeline to create premium results.
Industrial Die Cutting Machine Types
Many of our customers also wonder, what are the different types of cutting equipment? Here’s a quick overview of common precision cutting equipment.
Flatbed Die Cutting
Sometimes known as steel rule die cutting, this process uses a flatbed die cutting press and custom steel rule dies. For thicker material or minimal production runs, this is a useful die cut method.
Rotary Die Cutting
Conversely, rotary die cutting uses a rotary press. The user attaches cylindrical dies to the press. Most often, this method is useful for flexible materials and more voluminous production runs. A rotary die cutter is also more accurate than some alternatives.
Digital Die Cutting
Sometimes referred to as laser die cutting, digital die cutting doesn’t actually use dies. A computer controls blades, lasers and tool bits. When using low shear material, laser cutting is a cost-effective method that is also very precise. A laser machine also has a higher cutting speed.
Types of Cuts
Likewise, there are several different ways that you cut material. Whether you’re using a knife, blade, laser, die or die blade, there are multiple methods to die cut. Below is a quick overview.
Not completely separated from the original material, this die cut creates closely spaced holes outlining your desired shape. This method makes it easy to detach the shape at a later point.
This is useful when you have a backing layer. Kiss cutting slices through the top and adhesive layers but not the material that backs the compilation. Thus, you can easily peel the die cut design from an intact back layer.
Exactly as it sounds, through cutting goes completely through all layers of material. Consequently, this fully separates your custom shape from the original material.
Similar to perforating, scoring leaves a die impression at preset points. This score cuts through less than 50% of the material. Therefore, this reduces the thickness of the material which allows for folds.
Likewise, creasing creates a fold line on original material. Although, it differentiates from scoring in that the stress points differ.
How CTI Can Help!
Now, we’re to the most important aspect of your search for an industrial fabric die cutter – our team at CTI! Of course, you can invest in equipment and learn how to use it. However, as mentioned, that often takes time, space, employees and a flexible budget. Many companies simply don’t have all of those resources readily at hand. Moreover, the training, oversight and expertise needed can be overwhelming for small and even large companies. Not to mention, keeping supply chains running smoothly is an essential art. Hence, it’s wise to consider a contract or toll manufacturer instead of purchasing and running a die cut machine.
CTI can save you time, money and hardship as you consider hiring help in getting finished goods to your customers.
Consider Contract or Toll Manufacturing
At CTI, we do both contract and toll manufacturing. If you’re wondering what each involves, here’s a quick breakdown.
Initially, let’s explore the similarities. Their common bond is supply chain management. In both options, your company hires another company to manufacture a final product for you. Basically, you outsource a service, such as die cutting, on demand while you remain the brand owner of the final product.
The difference in toll manufacturing verses contract manufacturing is that in contract manufacturing, the company you choose supplies the raw material to compile your product as well. Rather than you exclusively sending your products to be compiled (as you would in toll manufacturing), a contract manufacturer not only completes the production process for you, they also supply the materials needed. This method provides an effective and quick way for you to extend your product line without taking on the burden of purchasing expensive equipment or providing storage areas.
Moreover, even if you already have your own equipment or are still considering purchasing it, contract or toll manufacturing is useful when you have rush runs. Or, if your equipment is overbooked. CTI can aid in those scenarios as well.
CTI’s Tried-and-True Process
Finally, all is naught unless you hire a company with experience and expertise. Our team has both.
Ultimately, we’ve built our success upon that over the years. During those years, we’ve perfected our approach and developed a tried-and-true process. This process ensures that we deliver superior products in a timely manner. We also understand that every client is unique. In return, we provide a unique solution to their unique situation.
First, we always have a thorough discussion concerning the needs of our clients and review our capabilities in relation to those needs. It’s imperative that these criteria line up and are a good match. Consequently, we can be certain of a successful outcome.
Research & Development
Once we determine that we make sense as your contract manufacturing partner, we go a step further. Research and development are something all contract manufactures should do. When a client needs a new process, is working with a new material or wants to develop an entirely new product, we explain our capabilities and our test/retest ethic. Finding a weakness is better when it happens early in the design phase than later on in production. We want to be certain there are no surprises!
The ability to inspect a quality product before we go into full production is important. We believe that a sample in-hand is worth more than a finished product down the line! To avoid major issues later on, we allow inspection of the product at any stage of the process.
Likewise, many manufacturers jump right from the research stage directly to production. This is risky. The full production run is an expensive operation. You want to be sure that there are no glitches in the first production of a new product. That mistake costs not only money; it costs time. Consequently, we firmly believe in a limited “pilot run” to be sure that things go smoothly in full production. Again, we prefer no surprises!
Finally, we reach the stage of production with confidence. Contract manufacturing service clients know that working with us and having the advantage of all of our preliminary testing, that the least stressful step will be the full production run of their finished goods. Instead of a fretful situation where a major, expensive problem could occur, our production runs are relaxed affairs with a celebratory atmosphere. A smooth production process is our goal.
Additional Contract Manufacturing Services at CTI
In addition to industrial die cutting, we offer other services to help our clients. Just a few include:
- Hot Melt Spray Coating
- Slot die coating
- Hot gravure
- Powder coating
- Belt Laminator
- Roll coating
- Hot roll lamination
- Water-based gravure coating and printing
- Meyer rod coating
- Knife-Over-Roll coating
For more information on any of these services, give us a call at 419-924-5566.
CTI’s Innovative Solutions
Speaking our diverse capabilities, here are some unique challenges we conquered for our loyal and diverse clientele.
- Adhesive Coating of Fiberglass for the Wind Energy Industry – The adhesive coating industry changes nearly as much as the wind itself. Thus, CTI remains on the cutting-edge for its customers who engage in this emerging industry.
- Water-Based Priming of PP Foam for Automotive Headliners – CTI is responsible for the development of the first pre-applied adhesive fabric for automotive headliners. While we wear that badge of honor with pride, we couldn’t have earned it in the first place without the motivation of a customer who needed a creative solution.
As you can see, we welcome challenges and thrive on the chance to conquer them so that our clients can flourish. Combining creativity and capability helps us do precisely that. Whether your business is small or large, or whether or not your project is minimal or massive, we would like to take on your challenge and master it!
Most importantly, we would love learn more about your project and discuss your needs further. If you’d like to hear about our superior solutions for an industrial die cutting machine and more, request a quote. Or, call us at 419-924-5566 to discover our talents and to put your production into motion!