Rotary Die Types

The two main types of rotary cutting dies are known as solid dies and flexible dies. Each die type has advantages and disadvantages, and choosing the optimal die type for your application should include consideration of all project specifications. Important considerations include:
  • Part material properties
    • Thickness
    • Compressibility
    • Cutting difficulty
    • Complexity – laminations
  • Part geometry
  • Waste removal requirements (slug or matrix removal)
  • Production volume requirements
  • Delivery timing
  • Production costs
    • Initial tooling cost
    • Overall manufacturing cost

Solid Dies

Solid rotary dies are manufactured from a single cylinder of steel. The die construction material may vary widely depending upon the requirements of the application. Solid die construction also allows for customization of cutting blade height, and elements such as engraved relief pockets, or waste removal features such as air ejection, vacuum, or stripping pins. Solid dies are considered more durable in general, as they can be made from numerous grades of tool steel, including premium alloy steels designed for maximum wear and toughness. For long-run, high volume applications, solid dies often prove to be the better overall value, based on durability and reduction in the number of required changeovers due to dull cutting blades that no longer provide adequate cut quality.

One of the greatest advantages of solid rotary dies is their ability to be resharpened to a like-new condition. Solid dies are typically heat treated throughout, or through-hardened, such that the die’s material properties (hardness, toughness) are consistent throughout the tool. A new blade edge with equal-to-new properties is created with each sharpening, prolonging the useful life of the tool. This is especially valuable when cutting product material that is abrasive or difficult to cut.

Advantages of solid dies

  • Strength
  • Durability
  • Customizability
  • Ability to resharpen cutting blades
  • Large range of possible die materials to
    fit application
  • Longer runs possible

Disadvantages of solid dies

  • Higher initial cost
  • Longer lead time to manufacture

At IMPACT we have two types of solid dies: narrow web dies and wide web dies. our solid dies types cover any product challenge you’re facing by providing solutions for food and medical grade products, and those are dealing with very abrasive materials. Our high precision tooling, made for tight tolerances, is long lasting and beneficial to your bottom line.

 

MRD1000: CORROSIVE RESISTANT TOOL STEEL
Food Grade
Medical

MRD2000: VERSATILE TOOL STEEL
Most Commonly Used
Average Yield Jobs

MRD3000: SUPERIOR TOOL STEEL
Medium-High Yield Jobs

MRD4000: ABRASIVE RESISTANT TOOL STEEL
Cryogenically Treated
Used for Abrasive Materials

MRD5000: PREMIUM PROPRIETARY TOOL STEEL
High Yield Jobs
Used for Challenging Abrasive Materials

Rotary Die Types - Flexible

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