Die cut a low density polyethylene large format part with a complicated high density cutting pattern accurately so they can match in a tall stack and form water passages for an ionic desalinization process. The density of the poly would distort significantly during cutting and would not maintain the size and shape of the cutting pattern on the die.


Feed the poly at a low tension into the dies and develop a dual direction distortion to the pattern and the die allowing the poly to naturally distort during the cutting process, but end up at the correct size and accuracy after cutting and relaxing. The solution created a speed mismatch between web and die and created a die diameter significantly larger than the nominal die diameter.


The low tension feed along with the dual direction distortion developed specifically for the cutting pattern size and pattern density proved to allow consistent relaxed part size, which allowed the ability to create production worthy consistent part size.