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ROTARY DIE CUTTING

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Rotary die cutting involves crush cutting material between the blades on a cylindrical die and an anvil which is a smooth hard cylinder. Though sheets of material can be fed through a rotary die, it is more common to cut material including foam parts in continuous roll form (defined in the industry as a web).

The capacity of a rotary die process is defined as the widest possible part that can be cut on the equipment. For example, a 10" capacity press can pass material which is 10.50" wide and cut off 1/4" per side of trim to make a 10" wide part. The length of the part depends on the circumference of the die.

Rotary cutting has a number of distinct advantages: The depth of cut can be controlled precisely between the anvil and the die which makes it ideal for 'kiss' cutting and results in long life and clean cuts for 'thru' cutting.

Cuts tend to be consistent since the dies are machined from a single piece of tool steel. The blades will break or wear out before moving. It is possible to make a bad cut by deforming the material going through the die.

Material can be processed at high rates of speed. The limiting factor for productivity rarely lies in the cutting. It is usually the material handling, the size of the rolls, or other in-line processes that limits the process speed.