Can the World Be Both Round and Flat? Butch Schomber, RotoMetrics, Eureka, MO, USA At one time or another, this question quicker deliveries and added converting fea- could have been answered no and everyone tures now available with rotary engraved would have agreed. In the new converting cutting dies, converters are beginning to re- world that we live in, the answer can be both. think the rotary diecutting platform. Once considered a process to produce simple tags What was once a This dual concept also applies to the ma- and labels, rotary diecutting continues to clear line between terials and end products our customers are evolve into what is considered more of a web asking us to convert. Some of these products fabrication process option. Web fabricating the capabilities of have not changed over the years, but new involves more than just printing paper la- flatbed diecutting ones are brought in each day that challenge bels and rewinding them onto a roll—rotary us to investigate new solutions in order to web fabrication can now create multiple lay- versus engraved meet demand. As the converting industry ered parts all in one pass. rotary cutting has expands into new markets, rotary diecutting continues to develop new processes and fea- What was once a clear line between the become very fuzzy. tures that are allowing converters to better capabilities of flatbed diecutting versus en- serve their customers. As our customers de- graved rotary cutting has become very fuzzy. mand quicker lead times between order date Flatbed was the go-to option for certain ma- and shipment times, speed is now a require- terials, specific shapes or shorter runs. ment that is as important as price. With the Today’s rotary cutters can be used to cut not Circle gasket die Automotive gaskets 6 The Cutting Edge April 2017 only web or roll form products, but are also of producing. The important point is that capable of cutting sheet fed products. With there are materials that we use every day features such as quick change die stations that fall between the two extremes men- and higher run speeds, rotary converting is tioned. Rotary engraved diecutters are used now offering a distinct advantage. The ben- every day to produce products from thin, one- With features such efits also include longer wearing, more cost- layer films or paper to multiple-layer con- effective cutting dies that are manufactured structions for common medical, automotive as quick change die to a much tighter tolerance than steel rule and electronic components. Not only are stations and higher dies. these parts being produced, but it is also being done at higher speeds and tighter tol- run speeds, rotary Rotary engraved cutting tools and equip- erances than ever before. An engraved cut- converting is now ment carry the outdated stigma of being only ting die is limited in run speed only by the for long run tag and label markets. This sim- process itself—the die has no limitations. offering a distinct ply is not true anymore, and investing to ex- With a cavity tolerance of +/- 0.0001" advantage. pand into either web fed or sheet fed (0.00254mm), it outperforms steel rule dies rotary-type cutting may now offer more op- in both speed and tolerance every day. These portunity than ever before. With the contin- features of speed and accuracy play a huge ued development of web fabrication roll in true costs and, therefore, opportuni- diecutting methods, rotary converting is ties. something to seriously consider for gaining new product offerings for your existing cus- Not only can rotary-type engraved cut- tomers as well as the expansion into new, ting dies be made to cut to controlled depths profitable markets. Folding cartons, gaskets, with extreme accuracy, they can also be made wound care, transdermal patches, medical as thru-cut tools to allow for single parts to devices, electronic components and filters are be collected at the end of the machine. Con- examples of products that are commonly verting platforms are available in web fed; being produced on rotary web/sheet fed roll to roll; or roll to part designs, as well as equipment today. sheet fed machines made to fabricate parts from single stacked product This continued development and expan- sheets. In web fabrication mar- sion into rotary web fabrication opened doors kets, the rotary engraved tools for the ability to produce parts from thicker offer methods to move or relo- materials such as gaskets and medical wound cate parts on the web. Utilizing care products. Rotary-based converting air ejection, vacuum or special equipment offers the ability to run and lami- designed pin ejection methods, nate multiple product layers in line to pro- slugs and waste can be removed duce tight tolerance fabricated parts in one easily and efficiently with this pass at reliably higher speeds than ever be- one pass process. Cut the part, fore. It must be noted that rotary diecutting strip the waste, remove the slug is not the answer for everything. Due to cer- and rewind or collect—one pass, Donut gaskets tain material characteristics and the effect done! This is being completed at of the rotary knife entering and exiting as it speeds that are unmatched in the crush cuts the product, material thickness flat bed process. and compressibility play an important role in result. Many times these challenges can be improved with input from your diemaker! Input such as the diameter of the cutting tool to ensure stability, compound blade angles designed to control part distortion or simple web path processes can play a role in the effort to address these challenges. By work- ing closely with an experienced diemaker, these obstacles can be minimized. Another example could be very thick, hard materials that can be only be cut with the tons of pressure available with a flatbed machine that rotary equipment is not capable Conventional vacuum tool April 2017 The Cutting Edge 7 Rotary diecutting machines are now be- It should also be noted that this type of ing designed to allow for removable anvil flexible tooling can also be utilized in many rolls and cartridge-style die stations that can flatbed presses. With assistance from your Forming anvil be quickly set up and slid in and out of the press manufacturer, it may be possible to de- converting path. The removable anvil feature sign a magnetic or wooden counterplate that technology will open doors to using this bottom roll to will allow the use of these tight tolerance continues to grow in form, drive or vacuum parts for removal or plates. replacement. Forming anvil technology con- design and tinues to grow in design and popularity as Rotary-type cutting equipment comes in popularity as converters move into new markets. What was many sizes and designs. Reach out to the lead- once just a cutting surface now can serve as ers of this industry and discuss with them the converters move an important part in the mating of two rolls parts that you hope to manufacture. As with into new markets. to create a new product. By having this op- just about anything, machines come in differ- tion available, parts can be diecut not only ent layouts and pricing levels. But there is one from the top down, but now also from the that will fit your needs. bottom up—and in the same station! Toler- ance control between these two tools is un- The same applies to rotary die manufac- matched, compared to trying to register two turers—be sure to choose one that special- steps, two passes or two stations in the manu- izes in the tools you need to meet your facturing process. customers’ expectations. Similar to flatbed/ steel rule suppliers, some are more experi- Flexible rotary dies can be an economi- enced than others in working with certain ma- cal option for thinner products. With the use terials and offer varied features to improve of a rotary magnetic cylinder, converters can life and cut result. purchase high tolerance flexible dies that are quick and easy to Choosing the right rotary diemaker is just change. These as important. Work with those who are expe- tools offer preci- rienced, with a full product line offering tight sion cutting results tolerance machine finished tools, tools options for both paper and that may be priced for shorter runs and tools film substrates. that offer web fabrication features that will When tight spacing make your life easier. Search out the one who or small shapes are offers dedicated support to the non-traditional required, flexible tag and label markets, who can offer specialty dies can be manu- blade angles and profiles to ensure quality factured and often cutting results. Look for a supplier who can shipped the next offer assistance and guidance as you investi- day. This type of gate these new opportunities. In short, do your tool can be an ef- homework! fective alternative to a solid die, offer- Could faster speeds and higher tolerance ing reduced ship- control affect your bottom line? Could rotary ping expense and converting open new doors? Maybe the world lower tooling costs. is both round and flat! The thin, flexible sheets are hard- ened and can be Butch Schomber is the New Product Innovation Manager for RotoMetrics. Butch may be reached chrome-plated to at 1-636-587-3600 or by email at extend die life, [email protected]. With over 60 making them an at- years of providing diecutting solutions, multiple tractive option. retool facilities strategically located for quick, re- They are easy to liable delivery and the most experienced technical mount and remove support team, RotoMetrics can offer assistance in from the magnetic tool planning before you hit press.