Die cutting is the process of using a die to shear webs of low strength materials, such as rubber, fiber, cloth, paper, corrugated fiberboard, paperboard, plastics, pressure sensitive adhesive tapes, foam and sheet metal. In the metalworking and leather industries, the process is known as clicking and the machine may be referred to as a clicking machine.[1][2] When a dinking die or dinking machine is used, the process is known as dinking.[1][3] Commonly produced items using this process include gaskets,[4] labels, cardboard boxes, and envelopes.
Die cutting started as a process of cutting leather for the shoe industry. It is now sophisticated enough to cut through just one layer of a laminate, so it is now used on labels, stamps, and other stickers.
Die cutting can be done on either flatbed or rotary presses. Rotary die cutting is often done inline with printing. The primary difference between rotary die cutting and flatbed die cutting is that the flatbed is not as fast but the tools are cheaper. This process lends itself to smaller production runs where it is not as easy to absorb the added cost of a rotary die.
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Rotary die cutting is die cutting using a cylindrical die on a rotary press. A long sheet of material will be fed through the press, and the die will rotate, cutting out shapes, making perforations or creases, or even cutting the sheet into smaller parts. A series of gears will force the die to rotate at the same speed as the rest of the press, ensuring that any cuts the die makes line up with the printing on the material.
Dies used in rotary die cutting are either solid engraved dies or some form of adjustable die. Engraved dies have a much higher tolerance and are machined out of a solid steel bar. Adjustable dies have removable blades that can be easily replaced with other blades, either due to wear or to cut a different material.
Dinking use special dies called dinking dies, or hollow cutters. The edges of the dies are usually beveled about 20° and sharpened. The material is punched through into a wood or soft metal block in order to not dull the edges.[5] The die may be pressed into the material with a hammer or a mechanical press.[6][4]
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