E402 PDF

IADD
INTERNATIONAL ASSOCIATION
of DIECUTTING and DIEMAKING
RECOMMENDED
S PECIFICATIONS &
S TANDARDS
RECOMMENDED SPECIFICATIONS,
STANDARDS
and
GENERAL INFORMATION
for the
DIECUTTING and DIEMAKING
INDUSTRIES
Revision 1, June 2002
Copyright© 1997-2002, The International Association of Diecutting and Diemaking, Crystal Lake, IL USA. All rights reserved.
PREFACE
The emphasis of this manual is to inform our membership of the specifications, standards,
and product information of the diecutting and diemaking industry.
This manual represents the beginning of a very important step in the explanation of the
specifications and processes of the products that are used in the diecutting industry. The manual
has been developed through many hours of research and gathering of information from the
diecutters, diemakers and vendors of our Association.
It is our intention, as new products and processes are developed, to continually update this
manual. This will allow the members of the Association to rely on this manual as the definitive
guide to the recommended specifications for products and processes used in our rapidly changing
industry. This manual contains an issue number and revision letter. The recommended
specifications include the revision number so members can make this a part of their quality system.
This allows for document control as required for ISO and other quality certifications. As the
manual is updated, members will receive the new information with a new title page and table of
contents showing the new revision numbers. Members needing proof of the current revision level
for audit purposes can request this information from IADD headquarters.
The IADD does not endorse or recommend any brands of equipment or other materials. The
appearance of an article or a particular brand of equipment within this manual is only used to
illustrate a concept.
Copyright © 1997-2002 International Association of Diecutting and Diemaking, Crystal Lake, IL USA. All rights reserved.
TABLE OF CONTENTS
Issue: 2 Revision Level: 1
TITLE PAGE
Preface
Introduction I
Table of Contents ii-iv
Chapter 1-- Flat Rule Rev.

General Information 1-1 R0
Specialty Rule Solves Diecutting Problems 1-8 R0
How Smooth Is Smooth 1-10 R0
Making A Point 1-11 R0
Specifications - Flat Cutting 1-13A R1
Creasing and Folding of Paperboard 1-16 R0
General Information - Flat Creasing Rule 1-18 R0
Specifications - Flat Creasing Rule 1-19A R0
General Information - Perforating Rule 1-21 R0
Specifications - Flat Perforating Rule 1-22A R0
Specifications - Flat Combination Perforating Rule 1-23A R0
Chapter 2 -- Rotary Rule

Innovations in Rotary Diecutting 2-1 R0
Choosing the Optimal Rotary Rule 2-2 R0
Rotary Rule Selection for Soft Anvil Diecutting 2-3.1 R1
Specification Definitions 2-4 R0
Specifications - Rotary Cutting Rule 2-6A R0
Specifications - Rotary Creasing Rule 2-7A R0
Specifications - Rotary Perforating Rule 2-8A R0
Specifications - Rotary Combination Perforating Rule 2-9A R0
Chapter 3 -- Punches
Types of Punches 3-1 R0
Punch Nomenclature 3-2 R0
Guidelines On How To Order Punches 3-4 R0
Specifications - Tubular Punches 3-5A R0
Specifications - Feed-Thru Punches 3-6A R0
Specifications - Cup Punches 3-7A R0
Specifications - Serrated Tubular Punches 3-8A R0
Specifications - Side Outlet Punches 3-9A R0
Specifications - Serrated Side Outlet Punches 3-10A R0
Specifications - Oblong Side Outlet Punches 3-11A R0
Specifications - Formed Oval Tubular Punches 3-12A R0
Specifications - Formed Oval Feed-Thru Punches 3-13A R0
Chapter 4 -- Counter Plates

General Information - Steel Counter Plates 4-1 R0
Creasing and Folding Paperboard 4-2 R0
Die with Steel Counter Drawing 4-4 R0
Specifications - Steel Counter Plates 4-5A R0
Steel Counter Channel Chart -
(Cylinder Board, Clay Coated News, Fourdrinier, S.B.S.) 4-6A R0
Steel Counter Channel Chart
(Kraft Coated, Bottle Carrier Stock) 4-7A R0
General Information - Plastic/Phenolic Counter Plates 4-8 R0
Die with Phenolic Counter Drawing 4-9 R1
Specifications - Plastic/Phenolic Counter Plates 4-10 A R0
Phenolic Counter Channel Chart 4-11 A R1
Reduced Bead Creasing 4-11.1 R1
Specifications - Reduced Bead Phenolic Counter Plates 4-11.3A R1
Specifications - Reduced Bead Crease Rule Types 4-11.4A R1
General Information Creasing /Scoring Matrix Strips 4-12 R0
E and F Flute Scoring 4-13 R0
Specifications - Creasing Matrix 4-14A R0
ii
Table of Contents (Continued)
Chapter 5 -- Cutting Plates

General Information - Hard Cutting Plates 5-1 R0
Specifications - Hard Cutting Plates 5-2A R0
Chapter 6 -- Chase Back Plates

General Information - Chase Back Plates 6-1 R0
Specifications - Backup (Backer) Plates 6-2A R0
Chapter 7 -- Ejection Material

The Role of Ejection in Diecutting 7-1 R0
Ejection Sponge: “The Important 16th” 7-3 R0
Monroe’s E-Z SetTM Speeds Die Rubbering! 7-4 R0
Thermoplastic Ejection Rubber 7-4.1 R1
Band Saw Tip 7-5 R0
Ejection Material -- Width vs. Height 7-6 R0
Specifications - Closed Cell Sponge 7-7A R0
Specifications - Open Cell Sponge 7-8A R0
Specifications - Cork or Cork/Rubber 7-9A R0
Specifications - Pure Gum Rubber 7-9A R0
Chapter 8 -- Dieboard
The Care & Feeding of Plywood 8-1 R0
Die Board Storage 8-2 R0
How to Keep Your Dieboards from Doing the Twist 8-3 R0
The 10 Most Frequently Asked Questions About
Laser Dieboard Cutting 8-5 R0
General Information Regarding Flat Maple Dieboard 8-7 R0
General Information Regarding Flat Maple Dieboard for
Dieboard Routing Systems 8-7.1 R1
Specifications - Flat Maple Dieboards 8-8A R0
Specifications - Flat Maple Dieboards for
Dieboard Routing Systems 8-8.1A R1
General Information Regarding Flat Birch Dieboards 8-9 R0
Specifications - Flat Birch Dieboards 8-10A R0
General Information Regarding Flat Birch Dieboards for
Dieboard Routing Systems 8-10.1 R1
Specifications - Flat Birch Dieboards for
Dieboard Routing Systems 8-10.2A R1
General Information Regarding Flat Beech Dieboards 8-11 R0
Specifications - Flat Beech Dieboards 8-12A R0
Specifications - Flat Permaplex Platinum Dieboards 8-13A R0
General Information regarding Rotary Maple Dieboards 8-14 R0
Specifications - Rotary Maple Dieboards 8-15A R0
Chapter 9 -- Automatic Rule Bending Machines

General Information Regarding Automatic Rule Bending Machines 9-1 R0
Automating The Processing of Steel Rule 9-2 R0
Automatic Rule Bending System -
Unmasking The Myth Of 100% Automation 9-3 R0
Comparison Charts 9-7 R0
Automation Of The Diemaking Process 9-15 R0
Automated Rule Bending Systems 9-18 R1
Chapter 10 -- Makeready Systems

In-Press Makeready Techniques for Automatic Platen Presses 10-1 R0
The One Hundred Year Problem 10-3 R0
Using the Spot-Less™ Blanket 10-5 R0
Converters Bid Farewell to Makeready Hassles 10-6 R0
Comparison Chart 10-7 R0
Chapter 11 -- Clicker/High Dies

Clicker/High Die Terminology 11-1 R0
Tolerance Requirements for Clicker/High Dies 11-4A R0
The Care and Maintenance of Clicker and High Dies 11-5 R0
iii
Table of Contents (Continued)
Chapter 12 -- Rotary Diecutting

General Information 12-1 R1
The Rotary Pressure Cutting Technique/Process 12-2 R0
Specifications - Flexible Plate Dies 12-4A R0
Chapter 13 -- Embossing
General Information Regarding Embossing and Foil Stamping 13-1 R0
Types of Embossing 13-1.1 R1
Embossing Glossary 13-1.2 R1
Diecutting and Embossing Guidelines 13-2A R0
Stamping and Embossing Dies 13-3 R1
Chapter 14 -- Thermal Dies

There’s Nothing Like a Hot Kiss 14-1 R1
Chapter 15 -- Plotters
General Information Regarding Plotters, Cutters, Scoring Machines 15-1 R1
Specifications - Plotters 15-2A R0
Chapter 16 -- Diecutting
History of the Diecutting Process in America 16-1 R0
Materials that are diecut 16-5 R0
“Diecutting Tips” from Preco 16-9 R0
Chapter 17 -- Rotary Diecutting / Soft Anvil

General Information Regarding Soft Anvil Rotary Diecutters 17-1 R0
Soft Anvil Rotary Diecutting Press Information 17-2 R0
Soft Anvil Rotary Diecutting Press Information Continues 17-5 R1
Chapter 18 -- Fluted Paper

Corrugated Flute Chart 18-1 R0
Chapter 19 -- Lasers
General Information Regarding Lasers 19-1 R0
Lasers System Standards and Capacities 19-1.1 R1
Rotary Laser Technology 19-1.7 R1
Specifications - Lasers 19-2A R0
Chapter 20 -- Miscellaneous
Specifications - Print to Cut & Emboss to Print Specifications 20-1A R0
Specifications - General Information - Total Press Tolerance 20-2A R0
General Information Regarding Rotary Precision Machining 20-3 R1
Hard Tooling Nomenclature (Combo, Class A and Blanking Dies) 20-5 R1
Information Needed for Hard Tooling Die Quote 20-6 R1
Comments/Corrections Form Inside Back
iv
CHAPTER 1
FLAT RULE
IADD Product Information
General Information Regarding Steel Rule
The following is a general guideline which can be used when choosing the proper rule, using type of
bevel, angle of bevel, and type of edge as the criteria. This information has been gathered from various
publications, rule manufacturers and knowledgeable industry experts.
There will be times when the rule that is typically used and/or recommended for an application will not
work well on that particular job. This may be due to a variety of reasons including material being cut, type of
ink, coating, or the press the job is running on. In most applications, the following information should be
helpful.
Rule Bevel:
1. Center Bevel - Used in 85% of all paperboard cutting.
2. Side Bevel - Designed to produce a square or flush cut on materials such as
gasket material or rubber. Generally, this bevel has a slight back bevel of .004"
so the edge does not roll over under pressure. Some rule manufacturers can make
this rule so that the edge is flush to the side. This is not generally recommended
because of the roll over potential.
3. Long Center Bevel - This bevel has the same cutting edge angle as the center
bevel, but the bevel angle changes approximately .010" down the edge to provide
better cutting ability. This is accomplished by alleviating or deflecting the added
pressure needed to cut thicker materials. The rule works well on some cardboard,
setup board, plywood, plastic, Kevlar,® etc.
4. Long Side Bevel - This rule has the same general purpose as the Long Center
Bevel, and also helps in reducing the crush in thicker die cut products.
Rule Edge:
1. Ground Rule - Ground rule is always the sharper of the two edges. This is true
because of the way the edge is made. The ground edge rule is slightly concave
because of the curvature of the grindstones. This produces a slightly steeper angle
than the “same” angle shaved rule. Grinding leaves a burr on the edge of the
rule.
The disadvantages of ground edge rule are:

1. Maintaining height tolerance.
2. Ground edge rule is not as smooth as shaved edge
potentially creating more dust during cutting.
These disadvantages are currently being corrected by manufacturers. There is a
polishing process that is being applied to certain manufacturers’ rule.
(Continued on next page)
IADD Product Information 1-1 R0

1- 1.0
The information shown has been supplied by manufacturers and distributors of these products.
This listing does not constitute endorsement by the IADD.
(Continued from previous page)
2. Shaved Edge - The most widely used edge in the industry today is the shaved edge rule. This
rule edge was developed to cut down on paper dust. A shaved edge rule may have a hardened
edge. This means that the edge on most (not all) shaved edge rules will be harder than the body.
Shaved edge rules have better height tolerance and a smoother cutting edge. It is generally
accepted that for paper board, a shaved edge (with certain exceptions) will give a better, cleaner,
more dust free cut.
The major disadvantage, is that the edge is not as acute as the ground rule edge.
Cutting Edge Angle:

The listed angles are generally available on cutting rule. The steeper the bevel, the more
shearing effect the rule has. This provides a cleaner cut with less dusting. Another positive
factor of a steep angle is the reduction in pressure needed to make the cut.
60 degree (American Standard)
52 degree (European Standard)
47 degree
45 degree
42 degree (introduced to create less dust)
Coatings:
Coatings are added to cutting rule for the following reasons:
1. To add lubricity to the cutting edge.
2. To fill voids in the bevel edge, giving a smoother cutting surface.
3. To extend the life of the die by reducing the wear factor.
Most coatings are either Molybdenum or Teflon. Coatings are also available with Titanium
and ceramic finishes. Some premium coated rules incorporate the three reasons above and
also work well on abrasive boards and inks.
Factors to consider which will help determine the correct or best rule to use:
1. What rule, if any, is currently being used?

A.! What is the experience with the
current rule?
2. What is the material being cut?
A.! Thickness?
B.! Recycled board - Y/N?
C.! Coated board - Y/N?
3. Is dust a problem?
4. What type of press (Platen/Cylinder)?
5. Type and color of ink?
6. Length of run?

1- 2.0
(2A). The thickness of the board to be cut will determine the bevel. “Dust Free” bevels (42, 45, 47)
are generally used up to 35 pt. board. Beyond 35 pt. edge deflection starts to occur.
The standard bevels, 52 & 60 can be used up to 50 pt. board.
When using thicknesses of more than 50 pt., it is recommended to change to a Facet (Long
Bevel, Double Double) bevel. Also use Facet bevel on harder board.
Side Bevel is used when closed shapes are involved or square cuts are required. “Square cut”
is defined as a straight cut with no crush.
(2B & 3). Recycled board generally will produce a dusty cut. To relieve most of
the dust you can use coated or polished edge cutting rule.
SBS Board may also use these rules, even though it does not produce as dusty a cut. Some
convertors can get by using standard rule.
(2C). Coated board may be coated with a variety of coatings in various thicknesses. Most coatings are
slightly abrasive. It is recommended to use any of the coated or polished rules.
If the coating is thick, giving it elastic properties, it is recommended to use either a premium
coated rule or a ground edge rule; however, an uncoated ground edge will wear very quickly.
A clay coated board is a prime example. Clay tends to stretch as it is being cut, and appears to
tear/crack.
(4). The type of press used, is an important factor, since most of the “dust free” rules will not work
as well on a cylinder press as they do on platen presses. Conventional angles, (52 & 60) work
best on cylinder presses because of the additional edge support of the rule. The edges of “dust
free” rules can roll over.
(5). When Titanium ink is used, the toughest, strongest, premium coated rule should be selected.
Titanium ink is very abrasive and will wear dies down very quickly.
(6). If the run is relatively short (50,000 impressions or less), a conventional, homogeneous rule can
be used. This type rule has the same hardness throughout and is not edge hardened.
When cutting any material having elasticity, using a ground edge rule is recommended. The sharper, serrated
edge created by grinding enables this rule to cut into the material before it can stretch or compress fully. A
partial list of elastic type materials includes; plastic, rubber, labels on a carrier backing, Kevlar,® film, some
laminates on folding cartons, and more.

1- 3.0
Tempers
Temper Rockwell Scleroscope Bend
Extra Hard 53-56 C scale 80 ½" dia.
Hard 49-52 C scale 75 1/4" dia.
#70 45-48 C scale 70 3/16" dia.
Medium Hard 41-44 C scale 65 1/8" dia.
Medium 36-39 C scale 55/60 1/8" w/ease
*Soft 86-94 B scale 35 Sharp
Dead Dead Soft 75-82 B scale 20 Severe
Edge Hard 49-52 B scale Sharp
Body Soft 90-100 B scale
*To be heat treated after bending
Applications
Extra Hard For extreme long runs, on straight work and circular bends ½"
in diameter and over.
Hard Tough, long-lived temper for straight work, slight bend and circular
bends ½" diameter and over.
No.70 Slightly milder than regular hard. Gives long life and when handled
carefully, takes 1/8" diameter bends.
Medium Hard Used where long wearing and good bending is required. Easily
takes bends as small as 1/8" in diameter and medium angular bends. This temper
is very popular.
Medium Slightly milder in temper than medium hard. Is capable of more severe
circular and angular bends.
Soft Used only where extreme bends are necessary.

1- 4.0
Rule Thickness
Point Decimal Equivalent Metric Equivalent
(inches) (mm)
1 0.014" 0.3556 mm
1½ 0.021" 0.5334 mm
2 0.028" 0.7112 mm
3 0.042" 1.0668 mm
4 0.056" 1.4224 mm
6 0.084" 2.1336 mm
8 0.112" 2.8448 mm
10 0.140" 3.5560 mm
Cutting Rule Faces

1- 5.0
Specification Definitions
Cut Edge Fidelity
Refers to the variation in the centricity of the cutting edge from the true
center or the rule.
Cut Angle Fidelity.

Refers to the variation in the angle of the bevel from the specified
angle.
Camber.
Refers to the variation in parallelism between the top or bottom edge
and a known straight edge. Camber is best checked by standing the rule
on edge on a surface plate and measuring the gap in the middle using
feeler gauges. It is possible to have reverse camber where the middle
touches the straight edge and the ends are up.
Dish.
Also known as concavity; dish refers to the vertical curvature of the
rule from its base to its tip. The degree of Dish can be determined by
laying the rule flat on a surface plate and using a dial indicator to
determine the amount of Dish. The Dish tolerance is measured per inch
(25mm) of height of material.
Twist
Refers to the condition where upon laying a rule flat against a surface
plate, the rule will be distorted in any direction on one side of the strip
and in the opposite direction on the other side of the strip.

1- 6.0
Coil Set
Refers to the distance between a known flat surface and the side of the
rule if laid flat across the surface. This specification applies only to rule
cut in lengths.
Length of Secondary Bevel

This specification pertains to cutting rule with a long or secondary
bevel. The tolerance refers to the maximum variation between what is
specified and what is measured.
Gullet Depth
Perf - Refers to the depth of the perf as measured from the cutting edge
of the Tooth (See Diagram 1)
Serrated Rule - Refers to the depth of the valley that occurs between
two points (See Diagram 2 )
Tooth/Space Fidelity
When dealing with perf of perf-score, it is normal to specify a
dimension for the tooth and one for the width of the gullet. The
tooth/space fidelity refers to the variance in the tooth and the space
(gullet) from their specified dimensions.
Run Out
Refers to the cumulative error which occurs in perf and perf score over
a given length of rule when the tooth is varying by a small amount.

1- 7.0
Specialty Rule Solves Diecutting Problems
Note: This article reprinted from IADD’s The Cutting Edge
Written by David Bialoglow, National Steel Rule Co., Linden, NJ, USA
As a company, we have been involved in problems that standard cutting rules cannot solve.
many aspects of the diemaking and diecutting One of the best examples of this type of problem is
industry, developing special products that have cutting foam. When cutting products such as foam,
solved particular problems for both flat and rotary standard cutting rule may not produce acceptable
diecutting. While most diecutting is done with a results. Standard serrated or flat die rules used to
very small percentage of available rules, one of the cut thicker foam products sometimes generate a
keys to success for special applications is to select serious problem with concavity on the cut sides of
the proper rule from the thousands that are now the product itself. By using “Deep V” serrated rule
available. such as 6, 5, 4.6 and 2.7 tooth, the problem of
concavity can be reduced. The difference in the
Choosing the Correct Rule Height tooth configurations is based on the desired results
One of the first aspects of steel rule that for the material being cut. More teeth per inch on
catches most people’s attention is the large the rule being used will produce a smoother finish,
assortment of rule heights available in sizes ranging whereas less teeth per inch will generally cut with
between 1/4" to 4" high (with inquiries for rule up less pressure.
to 8 inches high) and in thicknesses ranging from Another application where “Deep V”
2pt up to 8pt or greater. There are literally serrated rule is used is in cutting plastic film, such
thousands of different machines on the market that as your common supermarket bag. When trying to
require every rule size imaginable. Higher rule is use standard cutting rule and a cutting plate to cut
required when you are diecutting material that multiple sheets of plastic film, fusing may occur.
requires a greater amount of clearance such as (Fusing refers to the problem where the cut edges
blister packages, or if you are cutting a product of the plastic attach or fuse together, making it
where excessive compression can damage the impossible to separate the individual pieces.)
product. In choosing rule thickness, one must Products such as “Deep V” 11 and “Deep V” 13
consider the fact that heavier rule such as 6pt and tooth are more advantageous, as they pierce the
8pt will have greater beam strength when cutting material prior to cutting through (eliminating the
heavier material, however you will be sacrificing fusing problem). If you are cutting the plastic film
ease of bending as well the fact that it will be harder into a slot or with no anvil, you may use a rule with
to eject the cut part from the die. less teeth such as “Deep V” 8, 6, 5, 4.6, or 2.7
tooth. Certain tooth configurations such as 4.6 tooth
Cutting Foam and Plastic Film were designed specifically with bending in mind so
When diemaking or diecutting on platen that the teeth will line up when cutting a hand hole
presses, there is an almost limitless choice of rules on a supermarket bag while cutting into a slot.
available, since this process has been around for Occasionally the diecutter does not want to cut
nearly one hundred years. As long as it has been completely through the plastic film so it will hold
around, flat die cutting still encounters its share of together.

1- 8.0
Specialty Rule Solves Diecutting Problems
Folding Chipboard and Thick Plastic changed from side bevel to center bevel rule, many
One unique application we have observed is diemakers complained about the need to miter all of
the need for easier folding for heavy plastics and the trim knives. To solve this problem, we
solid fibre. Use of a product called Combination developed a line of premitered trim breaker knives
Cut & Cut has provided a solution to this problem. that were designed to eliminate the time required to
This product was specifically designed for the miter each blade as well as improve productivity on
folding of chipboard and thick plastic. Normal the diecutter.
combination perforating rule provides a primary Each blade is cut to a uniform 1.5 inches
cutting height and a secondary scoring height for and has a precision miter that precisely matches the
easier folding. Combination Cut & Cut provides the angle of the cutting rule. They are designed so the
same primary cutting height but offers a secondary height of the curved miter blade exactly matches the
cutting height for slit scoring as opposed to regular height of the lead and trail edge, while the straight
creasing. blade exactly matches the vertical knives. Another
feature of the curved blades is that they are made
Overcoming Creasing Problems from no notch curved rule, which eliminates the
Certain problems are more prevalent in chance of the blade backing away from the lead
certain styles of cartons. For example, slight edge due to the back notch sliding over the top.
variations in the dimensions of a box caused by
scores running with the corrugation create problems Communicating Leads to Future Changes
in the body in cover cartons commonly used for These are just a few examples of the
produce. To overcome this problem, we designed a specialty products that are available for some of
special creasing rule that has a bead running down those out of the ordinary diecutting jobs. Rule
the center that provides a crease with precise manufacturers can offer an incredible variety of
definition which results in an accurate fold. This tempers, bevels, tooth configurations, heights and
bead is centered on an eight on four laser crease so edging technologies, as well as special coatings.
cracking is minimized, yet there is no need to jig or Many of the special rule products were developed
laser an 8pt line. as a result of communication between diemakers or
diecutters and the rule manufacturers. As new
Mitering products are developed that present diecutting
Some products were developed specifically problems, it is this communication that will lead to
to save time and improve performance for both the next generation of cutting rules.
diemakers and diecutters. As the rotary industry

1- 9.0
How Smooth Is Smooth
Written by Andrew Weissman, J. F. Helmold & Bro., Inc., Elk Grove Village, IL, USA
It is widely accepted that a smooth bevel on results also suggest that coating a bevel may
cutting rule reduces dusting. As a result, rule actually increase surface roughness.
manufacturers have taken steps to improve bevel
smoothness. These steps may include secondary Bevel surface roughness was measured using
operations such as micro polishing and coating the a Hurtronic 3 Plus Profilometer manufactured by
bevel to improve lubricity. the Rank Taylor Hobson Company. The
profilometer measures surface irregularities as a
In an effort to help quantify the degree of diamond tracer point moves slowly across the
smoothness attained by these various approaches, surface, and a meter shows the average deviation in
we measured the surface roughness of four popular microinches (a microinch is .000001 inches).
cutting rules. Surface roughness was measured on both sides of
the bevel, referred to as front and back.
Following are the results we got on the four
rules measured: To help put surface roughness measurements
into perspective, the following are published surface
roughness measurements achieved by some common
Rule Type Surface Roughness finishing processes:
(Microinches)
Front Edge Back Edge
Shaved rule, edge Process Typical
hardened and coated 22-30 31-35 Surface Roughness
(Micro inches)
Through hardened rule, Grinding 4-63
ground and polished 12-13 11-12 Honing 4-32
Polishing 4-16
Shaved rule, edge
hardened 3-4 4-5 Lapping 2-16
Superfinishing 2-8
Through hardened
rule, shaved 2-3 4-6
If dusting is a concern to you, it may be
worthwhile to look more closely at the smoothness
These results suggest that bevels formed by
of the bevel you’re using. The bevel may actually
shaving can be approximately 3 to 4 times smoother
be rougher than you think.
than ground bevels, even after polishing. The

1- 10.0
Making A Point -- The Importance of Sharpness
Written by Steve Engle, [formerly with] Sandvik Steel Company, Benton Harbor, MI, USA
In today’s diecutting circles, much of the the bevel flanks, these burrs cause premature
talk concerning cutting rules has to do with the cracking during bending by the diemaker. In the
angle of the rule’s BEVEL. Interest in this area is early 1960's, a new method of edge sharpening was
certainly warranted, as research has shown the introduced: shaving. This technique involves coils
importance of slimmer bevel angles in relation to of material being transported through a fixed
the cleanliness of the cut or “dust reduction.” With carbide cutting tool to produce its cutting edge.
this focus being the case, an often overlooked Shaving yielded a beautifully smooth edge, with
characteristic of a cutting rule is the rule’s precise height accuracy, but at this time the
sharpness. sharpness could not compare to the ground product.
In the process of diecutting labels, lined or Through technical evolution, edge shaving
coated paperboard, plastics and other synthetic has vastly improved. Currently, premium shaved
materials, sharpness may be the most important rules are offering the sharpness of conventionally
feature of a rule. Despite this fact, sharpness often ground rules. This sharpness is clearly able to meet
goes unnoticed. the needs of most paperboard converting
The purpose of this article is to explain what requirements. However, in many cases these
sharpness is, how it is attained and when it is products do not possess the optimum sharpness
needed to achieve increased diecutting productivity. necessary for the diecutting of labels, plastics, and
Armed with this information, the diecutter is then lined paperboard. These materials differ from the
able to make a knowledgeable rule selection when standard recycled or virgin paperboard in that the
the need arises. outer surface stretches upon impact with the rule.
In the infancy of cutting rule production, While the angled bevel of the rule acts as a wedge
rules were placed in a vice and hand filed. It was to push apart the diecut piece, extreme edge
said that on a good day, a man could produce up to sharpness is required to cut these elastic surfaces.
fifty feet of rule. For example, label diecutters often tell of
The first mass-production of cutting rules situations where, upon inspection of a label run,
involved the edge manufacturing method of they see that the backing has been cut, yet the label,
grinding, which is still in use today. In this method, which initially contacted the cutting rule, remains
sharpness is accomplished by passing a coil of uncut. This is a graphic example of the outer
cutting rule through a pair of grinding wheels material stretching upon impact with the rule.
rotating in opposite directions. This process Extreme sharpness is required to diecut these
produces a reasonably sharp edge in a fairly products effectively.
efficient manner, but has some drawbacks. The Extreme sharpness is determined by
grinding process makes it difficult to keep the measuring the extremely small edge radius. The
exacting height tolerances required, and the method unit of measurement is the micron. One micron is
produces burrs. Located on the edge, these burrs equivalent to .001 millimeters or .00004 inches.
negatively affect the cut ability. When appearing on

1- 11.0
Making A Point -- The Importance of Sharpness
Today’s shaved rules vary in edge radii from penetrate and separate the elastic material more
6-14 microns, depending on the quality of the effectively.
manufacturer’s process. Premium shaved rules These new sharp edges must be protected to
ranged between 6-8 microns. These rules possess set optimum production from your tool. The rule
good sharpness (equal to conventionally ground manufacturers can vastly improve the life of the die
rules) and attain the necessary height tolerance, edge by hardening the steel. But a big factor in the
making them ideal for most paper converting. For process is the diecutting pressman. A good
label, coated paperboard, and plastic diecutting, makeready is required to protect the edge for
however, sharper edges are needed. optimum cutting performance. Press manufacturers
In 1993, state-of-the-art grinding machines obviously see this need, as prepress makeready
came on line and have been producing a precise 2-5 systems are becoming increasingly popular. In
micron edge, without the drawbacks of the addition, the extreme sharpness of the rule requires
conventional grinding machines. In fact, the height less cutting pressure.
tolerance of .0004 inches and burrless bevels are In conclusion, for best results when
attainable with the latest grinding method. Most diecutting labels, coated paperboard or plastics,
importantly, the edge sharpness of 2-5 microns select precise, sharp, specially ground cutting rule
offers a significant performance advantage over with the best dimensional accuracy.
what was once attainable. This sharper bevel will

1- 12.0
IADD Recommended Specifications
for
Flat Cutting Rule
Flat Cutting Rule - Side Bevel or Center Bevel - Under 2"/50mm

Size Specifications U.S. Metric Notes
Tolerances Tolerance
2,3,4 Point Height +/- .001" +/- .025 mm
2,3,4 Point Thickness +/- .001" +/- .025 mm
2,3,4 Point Temper +/- 4 points +/- 4 points
Rockwell C Scale Rockwell C Scale
2,3,4 Point Cut Edge +/- .002" +/- .051 mm
Fidelity
2,3,4 Point Cut Angle +/- 1 degree +/- 1 degree
Fidelity
2,3,4 Point Camber +/- .016" +/- .406 mm
over 30" over 76 cm
2,3,4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
2,3,4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
2,3,4 Point Coil Set +/- .125" +/- 3.175 mm
(Strip only) over 30" over 76 cm
2,3,4 Point Length of +/- .016" +/- .406 mm
Secondary Bevel
IADD Recommended Specifications 1-1-13A

13.1AR1
The specifications shown are the IADD recommended minimum tolerances.
Closer tolerances may be available — check with your supplier.
for
Flat Cutting Rule
Flat Cutting Rule - Side Bevel or Center Bevel - 2"/50mm and Over
Size Specification U.S. Metric Notes
Tolerance Tolerance
3,4 Point Height +/- .002" +/- .051 mm
3,4 Point Thickness +/- .001" +/- .025 mm
3,4 Point Temper +/- 4 points +/- 4 points
3,4 Point Cut Edge +/- .002" +/- .051 mm
Fidelity
3,4 Point Cut Angle +/- 1 degree +/- 1 degree
Fidelity
3,4 Point Camber +/- .032" +/- .813 mm
over 30" over 76 cm
3,4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
3,4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
3,4 Point Coil Set +/- .125" +/- 3.175 mm
3,4 Point Length of +/- .016" +/- .406 mm
Secondary Bevel

14.1AR1
for
Flat Cutting Rule
Flat Cutting Rule - Side Bevel or Center Bevel

Tolerance Tolerance
6,8 Point Height +/- .002" +/- .051 mm
6,8 Point Temper +/- 4 points +/- 4 points
6,8 Point Cut Edge +/- .003" +/- .076 mm
Fidelity
6,8 Point Cut Angle +/- 1 degree +/- 1 degree
Fidelity
6,8 Point Camber +/- .042" +/- 1.067 mm
over 30" over 76 cm
6,8 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
6,8 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
6,8 Point Coil Set +/- .125" +/- 3.175 mm
6,8 Point Length of +/- .016" +/- .406 mm
Secondary Bevel

15.1AR1
General Information Regarding Creasing Paperboard
Creasing and Folding of Paperboard

Written by James R. Barnes, Channel Creasing Matrix, Martinsburg, WV, USA
One of the properties of paper and perpendicular to the direction of machine travel.
paperboard that makes it desirable is its ability to In creasing the paperboard, two basic
accept a controlled fold in the middle of a stiff changes must take place. The board must be
sheet. This is made possible through a process partially delaminated, and it must be permanently
called creasing or scoring. deformed. This is accomplished by bending the
In order to understand the creasing process, board at a sufficiently sharp angle so that the
I think it is necessary to understand the nature of delamination and deformation occurs in the proper
paperboard. At the risk of being too elementary, I manner. The angle required to do this depends on
will begin at the beginning. the elastic properties of the board.
Paper and paperboard are produced from Here grain comes into play. Machine
natural cellulose fibers found in trees. This is done direction, being more elastic, may require a deeper
by taking the fibers apart and then putting them rule penetration or a more narrow channel to
back together under controlled conditions. achieve the sharper angle necessary to obtain
The principle methods used for taking the fibers equivalent deformation and delamination of the
apart are chemical, which removes the organic board.
binder between the fibers, and mechanical, which The delamination and deforming of the
tears the fibers apart physically. This pulping board results in a bead being formed on the
process produces papers of varying characteristics, backside which permits folding to take place
with the mechanical process producing fibers which without rupturing the top liner. If this bead is not
are shorter and weaker. The best example of this is sufficiently formed and is too near the surface of the
newsprint. board, when the board is folded, the bead will act
The fibers are then put back together to form as a fulcrum and cause the top liner to rupture.
a fibrous mat that eventually becomes paper plies. Proper bead formation results in the filler being
Individual plies are joined together to form simply squeezed out of the way during folding.
paperboard. During this process, various Board qualities and characteristics obviously
mechanical and chemical treatments are added to have a large effect on creasing. During creasing and
achieve the desired properties. folding, the top liner is put under tension and is
Although much of the world’s paper is made stretched. It must be of sufficient strength to accept
from virgin fiber, there is an increasing trend to the stresses needed to delaminate the plies and force
produce recycled paper. Here the paper is made the filler into a bead. Keeping in mind that an MD
from fiber that once was carton, newspaper or other crease stretches the board in cross machine
paper product. This reprocessing produces shorter direction and a CG crease stretches the board in
fibers which are not as strong as virgin fibers and machine direction, multi-ply paperboard will stretch
consequently affect the physical properties. more in the cross machine direction.
As a result of the manufacturing process, the Here the effect of moisture content comes
fibers of the paperboard tend to align themselves in into play. Board processed under conditions of very
the direction the paper machine travels. This fiber low humidity can cause creasing problems, because
alignment is called grain and is referred to as as the humidity decreases, the ability to stretch
machine directions (MD), fibers aligned in the decreases.
direction of machine travel, and cross grain (CG),

1- 16.0
Another area that is often overlooked is ply achieve equivalent deformation of the board. Here
bond strength. If it is too strong, you may have rule height becomes very important and MD creases
problems creasing. Here the selection of the board may require slightly more rule penetration to form
manufacturer is important. Can he/she produce a the proper bead.
board of good ply bond strength and yet one that An example of the above can be illustrated
will accept delamination when creased? in the creasing of .024" board. Selection of a 2
In the creasing of paperboard, there are point (.028") crease rule and applying the formula,
certain physical parameters that must be met in twice the board thickness plus the width of the
order to produce a good crease. You should know creasing rule, will result in a channel width of
what type of board you are working with, its .074" - .076" (2 x .024 + .028). This is a ratio of
characteristics, size and moisture content. Two of board caliper to channel width of 3.2:1, which
the most important physical parameters are creasing would be satisfactory for a MD crease, but
rule selection, both width and height, and unsatisfactory for a CG crease. Selection of a 3
establishing a proper female counter or creasing point (.042") rule would require a channel width of
matrix. .088" - .090" (2 x .024 + .042) and results in a
In selection of the proper creasing rule, ratio of 3.7:1 which would be satisfactory for both
there are two major considerations and both relate MD and CG creases.
to the female counter. First, the female counter or Remember, that in order for the board to
matrix should be approximately twice the board fold properly, there must be a proper crease. A
caliper plus the width of the creasing rule. Second, proper crease requires delamination and
the female counter should have a width of 3-1/2 to deformation of the board. In order to do this you
4 times the board caliper, although this value may must establish the correct relationship between
vary for MD scores because of the increased elastic board caliper, rule thickness and height and the
properties and the need to create a sharper angle to width of the female channel.

1- 17.0
General Information Regarding Flat Creasing Rule
Creasing Rule Height:
When matrix material is applied to the cutting plate before channels

are cut.
Height = cutting rule height (-) minus thickness of board.
When counter system is used.
Height = cutting rule height (-) minus thickness of board

(-) minus thickness of Matrix base material
(-) minus an added .002" to .004"
Creasing Rule Width:
2 pt. Creasing rule is generally used on stock up to .025"

3 pt. Creasing rule on stock .025" to .035"

1- 18.0
for
Flat Creasing Rule
Flat Creasing Rule

Tolerance Tolerance
2,3,4 Point Height +/- .001" +/- .025 mm
2,3,4 Point Camber +/- .016" +/- .406 mm
over 30" over 76 cm
2,3,4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
2,3,4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
2,3,4 Point Coil Set +/- .125" +/- 3.175 mm
IADD Recommended Specifications 1-19A

1- R0
19.0A
for
Flat Creasing Rule
Flat Creasing Rule

Tolerance Tolerance
6,8 Point Height +/- .001" +/- .025 mm
6,8 Point Temper NA NA
6,8 Point Camber +/- .042" +/- 1.067 mm
over 30" over 76 cm
6,8 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
6,8 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
6,8 Point Coil Set +/- .125" +/- 3.175 mm

20.0AR0
General Information Regarding Perforating Rule
The following is adapted from an article written by
Ed Mucci, Sr., National Steel Rule, Linden, NJ, USA
When selecting the proper rule for a particular pre-nicked rule for holding the multi-up diecut blanks
diecutting application, careful consideration is usually through the press. Pre-nicked rule allows the die to be
given to the cutting and creasing rules. Today there is delivered to the press ready to run. This product can
an enormous variety of bevels, points, hardness, and be used on flat and rotary dies, and can have a various
coatings that can be used to optimize die performance. nick sizes depending on the material being die cut.
A component of the die that few realize can cause
success or failure of the die is the perforating rule A suggested use of this product would be to
used. Used correctly, perforating rule can fold, hold place 1½" to 2" pieces with a centered bridge in areas
blanks together or tear. With an unlimited variety of of the die you would normally nick. A typical
heights, tooth combinations, and gullet depths, you corrugated application may use a 4-tooth perf with a
can achieve any of these results .028 nick. If the condition of the corrugated dictates
additional holding power, it is very easy to replace the
The most common use of perforating rule is prenicked rule with a 3, 4, or even 6 point nick.
folding. Even in this application, you have a great
deal of choices depending on the desired results. By The perfect vertical gap allows faster running
altering the width of the tooth and space you can speed and more uniform cartons and displays. For thin
achieve various degrees of resistance. The depth of materials, nicks from .004" are available. Like
the gullet can also be varied to form a specific crease perforating rule, the choice of tooth, gap width and
height. This product is commonly referred to as depth are unlimited. For rotary applications, the pre-
combination perf or perf-score. nicked rule should be approximately .030" lower than
the cutting rule to allow for the penetration of the
An excellent use of perf is for double rollover cutting rule.
scores. Perforating rule, that cuts only the inner liner,
is beneficial when double scores are used in trays or Many items require a diecut that can be neatly
displays where any cut on the outside of the sheet torn. While many people use Zipper rule for this
would be objectionable. Clean square folds are easily application, it is possible to obtain the same results
formed with minimum effort. This particular using perforating rule.
perforating rule is called E-Z Score, and is available
for flat and rotary dies. Few rule products have the variety of uses that
perforating rule has. By experimenting with the tooth,
While folding is the most common use of gap, and depth, you can maximize the performance of
perforating rule, the most under utilized use is the both the die and the diecut blank.

1- 21.0
for
Flat Perforating Rule
Flat Perforating Rule

2,3,4 Point Height +/- .001" +/- .025 mm
2,3,4 Point Cut Edge +/- .002" +/- .051 mm
Fidelity
Fidelity
2,3,4 Point Camber +/- .016" +/- .406 mm
over 30" over 76 cm
2,3,4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
2,3,4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
2,3,4 Point Coil Set +/- .125" +/- 3.175 mm
Secondary Bevel
2,3,4 Point Gullet Depth +/- .005" +/- .127 mm
2,3,4 Point Tooth to Space +/- .002" +/- .051 mm
Fidelity
2,3,4 Point Run Out +/- .020" +/- .508 mm
over 30" over 76 cm

1- R0
22.0A
for
Flat Combination Perforating Rule
Flat Combination Perforating Rule (Skip-Cut, Score)

2,3,4 Point Height +/- .001" +/- .025 mm
2,3,4 Point Cut Edge +/- .002" +/- .051 mm
Fidelity
Fidelity
2,3,4 Point Camber +/- .016" +/- .406 mm
over 30" over 76 cm
2,3,4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
2,3,4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
2,3,4 Point Coil Set +/- .125" +/- 3.175 mm
Secondary Bevel
2,3,4 Point Gullet Depth +/- .005" +/- .127 mm
2,3,4 Point Tooth to Space +/- .002" +/- .051 mm
Fidelity
2,3,4 Point Run Out +/- .020" +/- .508 mm
over 30" over 76 cm

23.0AR0
CHAPTER 2
ROTARY RULE
Innovations in Rotary Diecutting
Written by Meyer Ruthenberg, United Container Machinery, Glen Arm, MD, USA
In years past, the corrugated industry’s dryers without affecting the minimums through the
needs required a rotary Decatur that had the machine. This drying capability allows you to run
capability of printing. Today, those requirements multi-color work in-line, one pass, at higher
have shifted and broadened to a flexographic operating speeds, with the added ability to die cut
printing machine with the ability to diecut. in-line.
Since the introduction of the rotary Decatur The next design innovation introduced was
in the early 1960's, the basic construction of the servo rotary diecutting. If you were to look at the
machinery was unchanged, with gear driven pull performance curves generated on equipment without
roll construction. the addition of this feature, you would see dramatic
In the past six years, the design innovations peaks and valleys which relate to cutting rule on the
developed and implemented have had a major effect cutting die. These sharp curves would show what is
on flexographic rotary diecutting in the areas of happening in the machine during any revolution of
print and diecut registration, diecut accuracy, set-up the press as an effect of a conventional diecut
time savings and paper savings, yielding the overall section on the printer.
ability to print multi-color artwork and diecut When the conventional diecut section is
in-line at higher operating speeds without loss of removed and replaced with the servo section, the
print quality. gear train is eliminated between the last color and
To review, doctor blade ink systems, diecut section. The results are drastic. You would
specifically chambered blade systems, have replaced clearly see from performance curves that the spikes
the rubber roll fountains. Their ability to truly are drastically reduced and the color-to-color
meter a variety of inks enables the operator to print registration greatly improved. Additionally, overall
both sharp screen and line artwork, as well as diecut accuracy is greatly improved for single as
solids, with ink laydown being consistent regardless well as multiple-out jobs and enables plants to run
of operating speeds. orders without lead and trail trim.
Next, schematically looking at the overall To quantify the results, fingerprint and die
machines offered today, they have changed cut studies have yielded the following results:
dramatically. • Print registration in the order of .25 to
With the addition of vacuum transport, pull .5mm (.010 to .020")
rolls, pull collars and sheet guides have been • Print to diecut registration in the order of ±
eliminated. The ability to print and diecut warped .5mm ( .020")
board in register has been greatly improved. • Diecut accuracy in the order of ± .5mm
Additionally, with no pull rolls in contact with the (.020")
printed surface, print quality is enhanced, side trim Further, we conservatively estimate that
can be eliminated, pull bands are no longer required with the combination of servo drive technology and
and set-up time is reduced. vacuum transport, set-up times on each color can be
An added benefit of vacuum transport is the reduced by at least two minutes, and with the ability
ability to increase the distance between color to eliminate side, lead and trail trim, a 2% paper
sections in order to generate space for interstation savings can be achieved.

General Information Regarding Rotary Steel Rule
Choosing the Optimal Rotary Rule
Written by Edmund Mucci, Sr., National Steel Rule Company, Linden, NJ, USA
For those of you engaged in diemaking and associated with such a design.
diecutting on platen presses, the choice of what rule If your only consideration was blanket wear,
to use is almost limitless. Since platen diecutting a very shallow gullet such as those found on 20
has been around for nearly 100 years, there has tooth or 14 tooth shallow profile would be your best
been more of an evolution in terms of the choice. Since cutting occurs in the gullet of the rule,
technology itself and the available materials used in you might have cutting problems when the rule
the process. Today, there is an incredible variety of wears below the gullet. In the case of shallow gullet
tempers, bevels, heights, edging technologies and products, longevity of the cutting edge could be
coatings that can be combined to optimize compromised by designing a product strictly to
performance on these diecutters. minimize penetration. Generally speaking, the more
Rotary diecutting, in comparison, is a teeth per inch, the greater the pressure required to
relatively new technology having been developed in cut. In some cases the additional pressure will cause
the early 1960's. Though the rules used today are deeper penetration and you may actually increase,
vastly different from those used on the first rotary rather than decrease, the problem.
diecutters, it has only been in the past 10 to 15 When the primary objective is obtaining a
years that tremendous advances have been made. specific edge appearance, the choice of cutting rule
There are five performance considerations will have a significant impact on the results. If you
all rotary cutting rules must meet to one degree or are diecutting a display on a rotary Decatur and you
another: are looking for an edge that resembles the results
1) Pressure required to cut a given material from a flat die, a fine tooth rule would be an
2) Blanket penetration excellent choice. In order for fine tooth rule to
3) Edge appearance of the diecut blank perform effectively, you must be diecutting against
4) Wear (longevity of the rule) anvils that are in excellent condition. Worn or
5) Bendability uneven anvils may cause cutting problems due to
Technology allows us to design products to the lack of required resistance between the rule and
maximize any one of these characteristics. the blankets. On the other hand, if the edge you
If you wanted a cutting rule to cut with desire is more of a pronounced safety wave for
minimal pressure, you would design a very sharp hand assembly applications, products such as
tooth that has a very steep gullet angle. The sharp scalloped edge or SST work very well.
points of the rule would easily penetrate the board Under normal conditions, wear is not a
and allow the sharp gullets to cut with very little serious problem with today’s rotary rules, unless
pressure. The reason you would not want such a you are diecutting a particularly abrasive material.
product for actual use is the sharp teeth would cut If you find yourself diecutting abrasive materials,
deep into the anvils and cause premature blanket there are two possible solutions. The first is to go to
wear. There would most likely be bending problems a harder serrated steel.

Choosing the Optimal Rotary Rule
Normal rotary rule is between 33 and 36 grade of board being cut, the desired edge
RC, while certain specialty products like Klean Kut appearance and whether the rule is being used
have a Rockwell of between 40 and 44. If you have around or across the cylinder.
an application that does not require bending, almost The geometry of the tooth will affect the
all styles of rule are available up to 50 Rockwell. bendability of the rule, as well as the cutability.
When bending is a consideration, today’s rules are There are three classifications of tooth geometry:
available with an induction heat-treated edge. This V-Tooth, Radiused Gullet, and Radiused Tooth.
method provides the wear resistance of the harder The overwhelming majority of rotary rule sold are
rules with the bendability of normal rotary rule. the first two varieties. V-Tooth products are
The final performance criteria that must be met is generally available in 8, 10, 12, 16 or 20 tooth
bendability. Obviously, the softer a rule product is, configurations. Radiused gullet products are
the more bendable it will be. If you take this to an normally engineered to perform under specific
extreme, you can make rotary rule capable of conditions. For example, Klean Kut is designed to
accepting an X3 bend, however, it will not hold up reduce edge crush on long lead edge cuts on heavy
to the diemaking and diecutting process. board.
As you can see, rule can be engineered to The final characteristic that affects rule
solve virtually any problem encountered in performance is gullet depth. Deeper gullets wear
diecutting. Today there are approximately fifteen longer but tend to cut deeper into the anvils.
styles of rotary cutting rules being sold in the When it comes to selecting a rotary cutting
market. Each of these products has undergone a rule, one product is not optimal for all situations.
process of development and testing to ensure they By carefully evaluating the desired results against
meet the five performance criteria discussed earlier. the five performance characteristics all rule
Each of these products have three characteristics products must meet, you can select a product that
that determine how well they perform to this will provide the best chance of successful
criteria. The three characteristics are pitch, diecutting. When unique applications arise, your
geometry and gullet depth. best source for a rule recommendation is your rule
Pitch simply describes the number of teeth supplier. Likewise the development of future rules
per inch a serrated rule has. As stated earlier, the depends on making rule manufacturers aware of
more teeth per inch, the more pressure will be problems you encounter, as well as new products to
required to cut a given material. For soft anvil be diecut. By improving communications between
rotary diecutting, the optimal number of teeth per diecutters, diemakers, and rule manufacturers, the
inch is between 8 and 12. The choice of whether to improvements in rule over the past decade will
use 8, 10 or 12 tooth depends on factors such as the continue well into the next century.

Rotary Rule Selection for Soft Anvil Diecutting
Note: This article reprinted from IADD’s The Cutting Edge, January 2000
Written by Greg Zimmer, Zimmer Industries, Hawthorne, NJ, USA.
Soft anvil rotary conversion of corrugated has 5. Most of the rotary rules used today have a sharp
never been easy—and today’s more demanding point. This feature is excellent for piercing and
marketplace increases the challenge even further. setting and cutting the corrugated, but if a point is
Converting corrugated creates some very specific too sharp, it can create a weakness in the tooth that
and often predictable difficulties. In this article we may not stand up to the mallet in the diemaking
have four objectives: 1) To look at rotary rules in process, or the tough demands of running the die.
reference to their characteristics and possible The aim here is to have a tooth that is sharp enough
innovations; 2) To identify the difficulties usually to cut well, but also strong enough to stand up to
associated with corrugated conversion; 3) To offer general wear and tear.
possible approaches and or solutions; and 4) To
discuss how to effectively select rotary rules. 6. Another general feature of rotary rules is that the
bottom of the rule is usually less wide than the
General Rule Characteristics overall thickness of the rule. This is done to allow
As many of you know, there are three primary easier insertion into the dieboard. This feature is
manufacturers of rotary rules in the United States achieved in two methods. One calls for a breaking of
today. They are National, Simonds Notting Steel the corners, and the other calls for a rounding of
Rule Division and Zimmer. The general the corners. The choice is a simple matter of
characteristics of the rotary rules that these personal preference.
companies provide are as follows:
Problems and Solutions
1. Standard tooth patterns include 8, 10, 12 and 20 Now let’s identify and discuss the major reasons
teeth per inch, with occasional requests for 3, 4, for the difficulties most commonly associated with
4.6, 5, 6 and 16 teeth, though most of these corrugated conversion. Those reasons include:
occasionally requested rules are most often used for
non-corrugated applications. 1. The constantly changing character of
corrugated, which is primarily the result of changes
2. The standard bevels or cutting edges employed in its moisture content and/or its relevant
include: centerface, sideface, and off-center temperature. Dry, cool corrugated is a totally
centerface. different product than wet, warm corrugated, and
each will react differently in the converting process.
3. In general, (but not always) the more teeth per
inch, the more cutting pressure is required. Also in Though it is evident that a diemaker has no
general (but not always) the more teeth per inch, influence on the moisture content or temperature of
the lower or shallower the gullets or valleys of the the corrugated, he can offer important advice and
teeth are. Shallower gullets often require less assistance in dealing with these variables. In a plant
penetration to achieve good cutting and in many where moisture and temperature run on the high
cases may increase the life of the blankets or anvils. side, a limp, hard-to-cut board is often encountered.
Usually, the more teeth per inch, the better the Such board tends not to cut cleanly, often seems to
resultant edge appearance and edge feel. almost tear rather than cut and usually crushes
more readily. A possible approach to dealing with
4. The standard thickness supplied in the rotary these conditions would be to employ a cutting rule
industry is 4 point or .056", but in addition, 2, 3, 4, that could reduce the amount of pressure necessary
6 and 8 point are available for special applications. to achieve cutting. As stated previously, the fewer
teeth per inch, the less pressure needed to cut.
IADD Product Information 2-3.1 R1

Continued from previous page
Therefore, a choice of an 8 or 10 tooth pattern but remember the 20 tooth would require more
might be wise here. Keep in mind, though, that cutting pressure, everything else being equal.
coarser teeth normally have deeper gullets or
valleys and therefore may require deeper 4. Rotary diecutting has historically been seen
penetration into the blanket or anvil to finish the as less accurate than flat diecutting. The primary
cutting action. This fact can contribute to reduced reason for this lies in the fact that rotary diecutting
anvil life. requires cutting into a blanket rather than onto a
hard surface as is done in the case of flat diecutting.
2. Air, the very element that helps to create the The varying distances of necessary penetration will
unique properties of corrugated, also creates significantly vary the size of the blank being cut. In
several major problems in the converting process. general, the deeper the penetration necessary, the
Cutting or creasing a material that significantly smaller the created blank and of course, vice versa.
consists of trapped air automatically creates The depth of penetration necessary is affected by
difficulties. One of the most obvious is corrugated’s the condition of the blanket, operator efficiency and
propensity to crush, which is primarily due to the the amount and type of rule being used in the die.
necessity of material compression, which must take The blanket should always be properly maintained,
place before cutting can occur. Another problem creating a smooth, level surface to cut into. The
related to air in corrugated concerns the difference operator should make sure the proper cutting
in how cutting occurs when cutting with the flutes pressures are being used, the die and blanket are in
versus cutting against the flutes. Obviously, cutting good condition and that his machine is properly
against, or across, the flutes creates a more maintained.
supported, easier to cut medium, while cutting with
the flutes presents a less supported and therefore The dimensional accuracy of the die itself, of
harder to cut material. In general, a coarse (less course, is absolutely critical, and must always take
teeth per inch) pattern can also be helpful with this into account the proper use of shrink factors.
inherent problem, because it can reduce the Another important ingredient with regard to
necessary cutting pressure and in so doing, may diecutting accuracy is the rule used in the die. For
reduce potential crush. In the curved direction, it is example, rule height variations, or tooth form or
often helpful to have a relatively sharp tooth that depth inconsistencies can adversely affect
can better penetrate and “set” or hold the material dimensional accuracy. If penetration into the
in place as it is being cut. A less sharp tooth may blanket is kept to an effective minimum, blanket life
allow the material to move while it is being cut and may be increased, machine performance may be
may result in more of a tear than a clean cut. enhanced and dimensional accuracy can be
improved.
3. Corrugated should not be cut in such a way
that the resultant product edge is so sharp that it Clint Medlock of Stafford Cutting Dies had a
might promote paper cuts when being handled. This very interesting article in The Cutting Edge some
potential problem is often dealt with by slightly time ago. It dealt with the problems of achieving
breaking the product edges, which can be maximum accuracy from rotary dies and contained
accomplished by using a wave edge rule (often some very helpful and insightful information. Clint
employed in flat diecutting of corrugated) or by and I share the opinion that rotary dies can be made
employing a serrated rule, the usual choice in to achieve significantly greater accuracy than is
rotary diecutting. The coarseness or fineness of the now commonly being produced. Some of the areas
serrated tooth pattern directly relates to how that have previously been reserved for flat
smooth the product edges will be. For an obvious diecutting, because of accuracy requirements, may
example, a 12 tooth pattern will provide a smoother, soon be using rotary diecutting to achieve similar
finer edge than an 8 tooth rule. An even smoother results. In regard to improved rotary accuracy, it
edge could be produced by using a 20 tooth rule, should also be noted that companies such as Dicar

have made improvements relative to blanket In regard to rule properties relative to stripping,
performance with products such as the Equalizer, there are several choices of bevels, which can affect
which can help to compensate for some of the the stripping process. For many years, it was
inaccuracies often associated with rotary believed that sideface bevels created the perfect
diecutting. conditions for effective stripping. This type of bevel
tends to slightly crush one side of the product
(normally the scrap side) and leaves the other side
5) Weights and thickness of corrugated vary of the blank (usually the product side) basically
greatly, often requiring different approaches to uncrushed, often providing an ease of stripping
conversion and presenting different problems to be because the scrap is somewhat directed, controlled
dealt with. In essence, effectively handling varying and therefore easily removed. There are a few
weights and board thickness requires the diemakers who still believe that sideface is the most
achievement of a balancing act that will produce a effective bevel to use, but for the most part the
combination of the following: an acceptable product industry has switched to either true centerface or
edge, minimal cutting pressure and edge crush and off-center centerface bevels. The use of a true
a reasonable amount of blanket penetration and centerface bevel creates a product which is almost
wear. Unfortunately, many such attempts are identical on either side of the cut and both sides
subject to the old adage, “You can’t have your cake produced are better in both edge appearance and
and eat it too,” in that achieving one of these aims edge crush than the “bad” or scrap side of the cut
can often only be realized at the expense of produced by a side bevel. Neither side, though, is as
diminishing one of the other aims. For example, the good as the “good” side or product side of a sideface
cut. True centerface bevels are excellent
reduction of cutting pressure that may be
compromises and provide a solution to common
accomplished with a less teeth per inch rule is often cuts. They also remove the possibility of the
accompanied by reduced blanket life because the diemaker or diecutter placing the rule in the die
coarser tooth patterns normally require deeper backwards. The off-center center bevel is somewhat
penetration into the blanket. There are a couple of of a hybrid, which, because of its design, can
rotary rules now on the market, which claim to have provide some of the benefits of both a sideface bevel
more of a “universal” application, potentially and a true center bevel.
allowing the cutting of both standard and heavy
stocks with the same tooth pattern. Two examples of off-center centerface bevel
rules are the products Kleen-Cut and Supercut.
6. Operator efficiency obviously plays a very Being off center, there is of course the possibility of
large part in corrugated diecutting. Proper training putting the rule in backwards, but the people who
and motivation of the operator are extremely use this bevel seem to feel the advantages outweigh
important. Probably the most common operator the disadvantages. Regarding the issue of crush in
error is the overimpression and or over-penetration relation to stripping, it is critical that the rule used
of the die. does not overly crush the product edges. Stock that
has been unacceptably crushed, is often a nightmare
to strip, not to mention the compromising of
7. Effective stripping of the scrap is absolutely product strength.
critical to the successful conversion of corrugated.
Many variables affect this aspect of diecutting. One 8. It has long been a common practice to employ
of the most critical is the rubbering of the die. No curved rules in rotary dies that are somewhere
matter how good all other aspects of the diecutting between .020"-.024" lower than the straight rules
process are, if the rubbering isn’t as it should be, used in the die. This is based on the belief that
the die will not run effectively. There are several curved rules cut easier and with less pressure than
excellent manufacturers and or suppliers of rubber the straight rules, due to the lower number of teeth
that will be happy to assist you in this important penetrating at any one time.
area.

This long-standing theory is currently being Rule Changes and Improvements

challenged in the marketplace today by several
Let’s take a look at what else has been
rotary diemakers who are choosing to employ the
happening over the past few years in the rotary rule
same heights for both the curved and the straight
field:
rules. In asking one of the largest practitioners of
this new theory why he was bucking the normal
Rotary crease or score rules have been going
trend, he said there were several potential
through some changes over the years. The standard
advantages in using the same height for both the
creases are still widely used for many applications
straight and the curved rules. The first advantage
and for the most part do the jobs they were meant
he stated was that this configuration allowed the
to achieve. When a change in a die might call for a
operator greater latitude in the running in of the
wider crease, say to a six point or even an eight
die in trying to obtain the optimum efficiency of the
point crease, and the diemaker can’t or does not
die. He also mentioned that curved rules do not
want to re-cut the board, there are crease products
damage the blanket as much as straight rules do.
available that have a four point body and a six point
This being so, the curved rule possibly penetrating
or eight point face. This allows the changing of the
more deeply does not create a blanket wear
width of the crease face without having to re-cut the
problem. The converse of this being that the use of
dieboard. There is also a “waved” crease rule in the
a standard configuration, with a higher straight
marketplace that claims to improve creasing in
rule, permits the straight rule to penetrate more
certain applications.
deeply and potentially can create more blanket
wear.
In regard to curving rotary rules, one of the U.S.
manufacturers has created the ability to curve
The jury is still out on this issue, but we
without the use of notches. For special applications,
strongly believe there is good reason to examine
this capability can provide more accurate curving,
this theory more closely. It might be an interesting
make curved perf rules stronger and can hold the
idea to do some intensive field testing to confirm or
rule in the dieboard more securely. The possible
deny the benefits of this new approach. Granted, as
disadvantages of using rule curved in this manner
rule manufacturers we might have a slight bias on
include that it is more difficult to insert, and to cut
this issue, as it would certainly make our lives
and notch. Perforating and cutscore rules used in
easier if we could cut our inventory of rule heights
rotary diemaking are relatively simple and
by 50%.
standard. The most commonly ordered sizes are
usually .937 high with tooth patterns of 1/4 x 1/4",
9. Effective nicking of corrugated has often
or 3/8 x 3/8" or 1/2 x 1/2" They are available in
proved to be problematic. There is a new rule that
standard face or serrated styles. One possible thing
may aid in that area. especially in relation to light
to look for in a perf or cut-score is the proper and
corrugated. It is a pre-nicked rule that may be used
consistent alignment of the spaces of the perf with
for either rotary or flat applications. Simply
the notches on the bottom of the rule. When the
explained, this rule uses the idea that many small
alignment is off, a tooth and notch may fall in the
nicks can provide equal or greater strength than a
same place, thus creating a very weak area because
few larger nicks, and by using a sleek bevel and
of the small amount of steel that is left between the
uniformly placed smaller nicks, this rule can
notch and the bottom of the tooth. The best
produce product edges that are superior in terms of
alignment is provided when the rule manufacturer
both appearance and feel or touch. Because there
punches the top and bottom of the rule at the same
are so many of these smaller nicks, the strength
time, with the same stroke.
they achieve does not compromise the effective
conversion of the corrugated.

Choosing the Right Rule particular application. Unfortunately, there are no

In choosing an effective rotary cutting rule, here pat answers for this problem. Quite often, solutions
are some important things to look for: only come from years of experience.
a. Consistency of the following: rule height, I.D.’s
of curved rules, degree of bevel, notch A possible tip here for diecutters—it certainly
isn’t always possible, but when you are able to pick
placement (at correct and uniform center
the order of jobs to be run, it’s a good idea to run
distances,) tooth form, bendability, and burr any dies that have more teeth per inch before
free teeth. running the jobs that have less teeth per inch. That
b. Ability to stand up to the mallet. way the blanket stands a better chance of being in
c. Clean, rust free product. good shape when the less teeth or coarser teeth dies
d. Safe packaging and ease of dispensing. are run.
e. A fair price.
We believe that a step in the right direction
f. From stock deliveries on standard items. would be the diemaker’s choosing a cutting rule
g. Reasonable turnarounds on special made items. that is as close to universal in application as
possible.
The bottom line is that there are a huge amount
of variables to be considered in the wise choice of a Possibly, the standard rule that may come
rotary cutting rule that will be effective in the closest to being universal in its applications, is a 10
widest range of applications and will effectively tooth true centerface with equal serrated tooth
address a lot of the problems we’ve been discussing patterns on both sides of the bevel. By looking at
in this article. It is our opinion that there are some what product the industry uses most today, it
significant advantages for both the diemaker and appears that many people share that opinion. This
the diecutter in using the same tooth pattern with is a tooth pattern that effectively provides the
some consistency. following:
a. A cutting power that approaches that of 8
For the diemaker, predominately using the same tooth.
tooth pattern allows the carrying of a smaller b. A penetration between that of 8 tooth and 12
inventory, and lessens the chance of making a tooth, providing good blanket life.
wrong choice of rule by trying to find the “perfect” c. An edge appearance better than 8 tooth and a
choice for every application. For the diecutter, the little less than that of 12 tooth.
advantages may include their operators better d. An ability to cut virtually all light boards and
understanding of how to consistently run these most of the heavy stocks too.
similar dies, the probable reduction of over or under e. An all around excellent compromise that
impressing a die, a consistent edge appearance, and doesn’t give up anything at all critical in
(by using the same tooth pattern) they will basically relation to overall effective rotary diecutting.
require the same depth of penetration job to job. There is certainly no rule that will perform
Here’s an example of why this is so important. If equally well on every job, but the 10 tooth rule
several dies were run that use a deeply penetrating seems to best approach the earning of the term
tooth (usually created by a coarse or less teeth per “universal.” There will certainly be occasions
inch rule), the blanket would become somewhat when other tooth patterns will need to be used,
chewed up (but would probably still be effective for but those times should be relatively few.
deeply penetrating dies). If a shallow penetrating
die (often created by a higher number of teeth or The three American rule manufacturers
finer rule) were then run, there is a distinct previously mentioned, Simonds Notting Steel Rule
possibility that the shallower teeth would not cut Division, National Steel Rule and Zimmer have
properly because the blanket would not effectively each earned international reputations as rotary
support the cutting action. It would be a bit like the rule suppliers and any of the three would be more
tooth trying to cut into air. A tooth must meet than happy to further assist you in the proper
resistance to cut properly. The real trick here is for selection of the right rotary rules to best suit your
the diemaker to know when his chosen standard specific needs.
tooth pattern is not going to be effective in a

Cut Edge Fidelity
Refers to the variation in the centricity of the cutting edge from the true
center or the rule.
Cut Angle Fidelity
Refers to the variation in the angle of the bevel from the specified angle.
Camber
Refers to the variation in parallelism between the top or bottom edge and
a known straight edge, Camber is best checked by standing the rule on
edge on a surface plate and measuring the gap in the middle using feeler
gauges. It is possible to have reverse camber where the middle touches the
straight edge and the ends are up.
Dish
Also known as concavity, dish refers to the vertical curvature of the rule
from its base to its tip. The degree of Dish can be determined by laying
the rule flat on a surface plate and using a dial indicator to determine the
amount of Dish. The Dish tolerance is measured per inch (25mm) of
height of material.
Twist
Refers to the condition where upon laying a rule flat against a surface
plate, the rule will be distorted in any direction on one side of the strip
and in the opposite direction on the other side of the strip.

Coil Set
Refers to the distance between a known flat surface and the side of the
rule if laid flat across the surface. This specification applies only to rule
cut in lengths.
Length of Secondary Bevel

This specification pertains to cutting rule with a long or secondary
bevel. The tolerance refers to the maximum variation between what is
specified and what is measured.
Gullet Depth
Perf - Refers to the depth of the perf as measured from the cutting edge
of the Tooth (See Diagram 1)
Serrated Rule - Refers to the depth of the valley that occurs between
two points (See Diagram 2 )
Tooth/Space Fidelity
When dealing with perf of perf-score, it is normal to specify a
dimension for the tooth and one for the width of the gullet. The
tooth/space fidelity refers to the variance in the tooth and the space
(gullet) from their specified dimensions.
Run Out
Refers to the cumulative error which occurs in perf and perf score over
a given length of rule when the tooth is varying by a small amount.

for
Rotary Cutting Rule
Rotary Cutting Rule

Tolerance Tolerance
4 Point Height +.005" +.127 mm
-.000" - .000 mm
4 Point Thickness +/- .001" +/- .025 mm
4 Point Temper +/- 4 Points +/- 4 Points
4 Point Cut Edge +/- .002" +/- .051 mm
Fidelity
4 Point Camber +/- .032" +/- .813 mm
over 30" over 76 cm
4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
4 Point Coil Set +/- .125" +/- 3.175 mm
4 Point Back Notch +/-.062" +/- 1.575 mm
Variation over 60" over 1.524 mm
4 Point Depth of +/-.010" +/- .254 mm
Bottom Notch
4 Point Curvature +.000" +.000 mm
(Inside Diameter) -.125" -3.175 mm
IADD Recommended Specifications 2-6A R0

2-6.0A
for
Rotary Creasing Rule
Rotary Creasing Rule

Tolerance Tolerance
4 Point Height +/- .001" +/- .025 mm
4 Point Camber +/- .032" +/- .813 mm
over 30" over 76 cm
4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
4 Point Coil Set +/- .125" +/- 3.175 mm
4 Point Back Notch +/- .062" +/- 1.575 mm
Variation over 60" over 1.524 m
4 Point Depth of +/-.010" +/- .254 mm
Bottom Notch

2-7.0A
for
Rotary Perforating Rule
Rotary Perforating Rule
Tolerance Tolerance
4 Point Height +/-.001" +/- .025 mm
4 Point Cut Edge +/- .002" +/- .051 mm
Fidelity
4 Point Cut Angle +/- 1 degree +/- 1 degree
Fidelity
4 Point Camber +/- .032" +/- .813 mm
over 30" over 76 cm
4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
4 Point Coil Set +/- .125" +/- 3.175 mm
4 Point Gullet Depth +/- .005" +/- .127 mm
4 Point Tooth Space +/- .002" +/- .051 mm
Fidelity
4 Point Run Out +/- .032" +/- .0813 mm
over 30" over 76 cm
4 Point Depth of +/-.010" +/- .254 mm
Bottom Notch

2-8.0A
for
Rotary Combination Perforating Rule
Rotary Combination Perforating Rule (Skip-Cut, Score)

Tolerance Tolerance
4 Point Height +/-.001" +/- .025 mm
4 Point Cut Edge +/- .002" +/- .051 mm
Fidelity
4 Point Cut Angle +/- 1 degree +/- 1 degree
Fidelity
4 Point Camber +/- .032" +/- .813 mm
over 30" over 76 cm
4 Point Dish +/- .002" +/- .051 mm
over 1" over 25 mm
4 Point Twist +/- .042" +/- 1.067 mm
over 30" over 76 cm
4 Point Coil Set +/- .125" +/- 3.175 mm
4 Point Gullet Depth +/- .005" +/- .127 mm
4 Point Tooth Space +/- .002" +/- .051 mm
Fidelity
4 Point Depth of +/-.010" +/- .254 mm
Bottom Notch

2-9.0A
CHAPTER 3
PUNCHES
General Information Regarding Punches
Types of Punches
Note: This information provided by Richard Clements, Technical Manager
Ken Die Cutting Supplies, Inc., Carson City, NV, USA
Tubular Punches outlet punches are used when your application calls for
Tube punches are the most economical of all of the scrap to be ejected - as in feed thru - but this punch does
punches and are used for the widest range of not require the use of a bolster plate. Other than the
applications. Slugs cut by a tube punch do not feed thru location of the exhaust hole for the slugs, differences
the punch, but are left in the product being cut with the between the feed thru punch and the side outlet, are that
help of die ejection. A standard tubular punch by the side outlet is machined out of a solid piece of steel,
definition is a piece of 16 gauge tubing that has a bevel and it’s use of a shoulder. A side outlet shoulder is
machined on one end to a specific size. Tube punch cut defined as the machined area of the punch from the top
sizes span the decimal chart in both millimeter and inch of the cut edge to just above the exhaust chute.
measurements and can be machined into virtually any The most common type of side outlets are
custom size. A quality tubular punch should have a standard and heavy duty. The heavy duty side outlet is
chamfer on the bottom on both the inside and outside to used for thicker, heavier, abrasive materials, has an
aid in ease of insertion into the dieboard. The base size elongated shoulder and often includes a “knurl.” A
should have a .000" to .003" tolerance, the cut edge knurl is a raised portion located at the bottom of the
bevel should be virtually free of tool marks and the cut punch - similar in texture to a ratchet handle. It is
edges should be razor sharp. Springs are available in approximately .005" to .010" larger than the base size
tube punches to alleviate the need for die ejection. These of the punch and is 1/4" wide. The knurl is used to
springs should protrude approximately 1/16" from the prevent the punch from spinning or becoming
cutting edge. A quality tube punch will also be clean of misaligned in the dieboard. The standard side outlet is
scale, free of burrs, have a case depth of .003" to .005" used for easier to cut, medium to thin materials. It has
and a surface hardness of 58-60 Rockwell. a shorter shoulder than does a heavy duty and does not
include a knurl unless specified. A quality side outlet
Straight Wall Punches: should be razor sharp, free of tool marks, scale and
Straight wall punches are used for applications with burrs. It should include a slight support bevel on the
minimum punch space allotment where the base size of inside for strength as well as the undercut which
a standard tubular punch would be too great. Straight prevents the slug from jamming the punch before it
wall punches cause less distortion of cut size in thicker enters the exhaust chute.
materials. The slugs cut by this punch are left in the
product through the use of ejection or springs and share Cup Punches
the tubular punches tolerances and quality guidelines. Cup punches are strong, solid steel punches that use a
spherical shape to cut, compress and remove the slug.
Feed Thru Punches They are often used in place of a tube with spring
In a feed thru punch, the slug exits the punch through combination and offer accurate concentricity from cut to
the bottom rather than the side as in side outlets. Feed base. Standard cup punch sizes range from 1/32 to
thru punches are used when the application calls for the 31/64.
scrap to be removed from the product rather than being
hand stripped at a later time in the manufacturing Custom Punches
process. Feed thru’s must run on a bolster plate which Custom punches are seamless and can be manufactured
supports the die while at the same time allowing the to virtually any shape or size. They are used when high
slugs to feed thru where they are vacuumed, blown tolerance, accurate cuts are required and where rule
away, or otherwise disposed of. Feed thru’s are would fail. Custom punches can be used to produce
constructed from thin wall tubing which is spun or sized everything from high tolerance flex circuits, to
then re-machined to your specific cut size. This method components used in military aircraft, to the gasket in
assures the proper relief for slug ejection. Feed thru your car.
specs and sizes offered are much the same as a tube and
straight wall, except that the feed thru’s inside chamfer
is minimal, the cut edges have a slight support bevel on General
the inside for strength, and they do not come with Punches come in a variety of heights - the
springs. most common being .937" and each can be altered to
meet your specific application.
Side Outlet Punches Punch life is affected by the material being cut,
The slug of a side outlet punch feeds through an the application for which the punch was designed and
exhaust chute machined into the side of the punch. Side operator error.
IADD Product Information 3-1 3-1

R0
Punch Nomenclature
Cut edge: Springs:

The cut edge is the working end of the punch and A very common method of ejecting the scrap from
usually varies from 20 - 30 degrees per side. The a punch is the use of a spring. The spring usually
lesser the cut edge bevel, the less pressure it takes protrudes 1/16" above the cut edge of the punch and
to cut - therefore preventing a distorted cut. All cut has a working range of about .100" of travel.
edges are machined, unlike rule which may be Springs are most common in tubing punches, but
ground or shaved. can be used in virtually any style of punch.
Base: Undercuts:
The base is the body of the punch which supports All self cleaning and feed thru punches must have
the cut edge. Bases come in many shapes. The base undercuts. This will reduce the pressure it takes for
should always have a plus tolerance from “on size” the punch to remove slugs. If the undercut is
to +.003. A base should never be under size. This inadequate, the punch may break or work as a
will make for a loose fit. cavity punch leaving the slug in the work rather
than removing it.
Bevels:
Usually there are three types of bevels... Center, Wall thickness:
Inside, and Outside. Center bevel is the most The most common wall thickness is .060 which is
common of the three. On stock that is .014 or less, comparable to 4 Pt. rule. This wall thickness is
it does not matter which bevel you choose - as it needed for maximum strength on standard
will not influence the cut. applications, but can vary depending on your
specific application.
Support bevels:
A support bevel is very critical to the performance Shoulder:
and life of a punch. This bevel will add strength as A shoulder is measured from the top of the cut
well as stop chipping and peening of the punch’s cut edge of a punch down to the solid base. The ideal
edge. For example, a ½" base punch can not shoulder should be flush with the die board.
measure an exact ½" cut because of the 1/64" Shoulders may vary in self cleaning punches
outside support bevel that is machined onto the because of strength needed to support the cut edge.
punch to achieve concentricity. The cut size These punches are preferably machined with the
becomes 31/64" diameter. This also applies to a ½" shortest shoulder possible because the pressure
I.D. tube on a 9/16" base. The 1/64" inside required to push the slugs through a long shoulder
support bevel makes the punch size a 33/64" cut could lead to breakage of the punch.
diameter. If the support bevel on a self cleaning
punch is too big, the punch requires too much Bridge:
pressure to pick up the slug and will act as a cavity The bridge is the space between the shoulder and
punch leaving the slug in the work rather than the top of a self cleaning exhaust. The longer the
removing it. cut size - the thicker the bridge needs to be. If the
cut length of a punch exceeds approximately 1-1/8,"
Cavity: a special exhaust must be designed.
A cavity is a machined pocket on the inside of a cut
edge. This pocket can vary in depth depending upon
application or machining limitations. A standard
cavity depth should be 5/16" to accommodate
standard die ejection.

R0
Punch Nomenclature
Exhaust - "self cleaning": used to keep the punch from being pulled through
The exhaust chute on a self cleaning punch can be the die board by the material. Pins can be used on
out the side or the end of the punch. An exhaust is a heavy solid base punch, which may hang upside
a machined opening in a punch which allows the down in the press, to keep the punch from falling
material to exit through and out of the punch. The out of the die board.
exhaust should be as high as possible from the
bottom of the self cleaning punch so that the scrap Height:
can exit as efficiently as possible. Each die cut slug Height is the overall length from the top of the cut
pushes the next until they exit the punch. edge to bottom of the punch. The height of the
punch is usually precision ground to assure proper
Exhaust - "chisel": tolerance.
The chisel style exhaust is used when the bridge of
a punch exceeds approximately 1-1/8." Above this Nicking:
length, the punch may flex over the bridge area. The purpose of a nick, or a deliberate break in the
The chisel depth is usually half of the material cut edge, is so that the slug stays in the die cut part.
thickness so that the first time the punch cuts the As the slug remains partially connected to the
whole slug is removed. During the second cut, the material, it is easier to handle without the slug
fore mentioned slug is cut in half and exits the falling out. If more than one nick is required, they
punch in two pieces. should be symmetrical in spacing on the punch. A
nick is usually about .010-.030 wide depending
Exhaust - "feed thru": upon your requirements. Punches can be ordered
The feed thru exhaust is as a standard +.030 with nicks installed - but are usually put in by the
larger than the cut size of the punch and usually has diemaker.
the same shape as the cut. All feed thru punches
must be used in conjunction with a bolster plate. Serrations:
Just about any punch can be serrated. The purpose
Chamfer: of the serration is to relieve the cutting pressure so
A chamfer is a 45 degree angle machined onto the that the punch does not crush or tear the material
bottom of a punch. This allows the punch to be when cutting. The most common materials using
inserted into the die board without shaving the sides serration are corrugated and foam rubber. The
of the hole. serration will minimize scaving (hour glassing) of
the material. When cutting material containing
Knurl: string or threads the serrated punch often works
Knurls are most commonly found on self cleaning best. Serrated punches must always cut into a soft
punches. The knurl is machined onto the bottom of pad. Any tooth per inch (t.p.i.) can be ordered. The
the punch and is approximately 1/4 long . A knurl most common teeth per inch are 8-12 for corrugated
resembles the rough surface of a ratchet handle. 12-14 “shallow profile” for cutting foam.
The straight knurl is cut into base of the punch and
raises the surface approximately +.010 from the Heat treat:
base diameter. The purpose of the knurl is two- Most common tube punches are made of low carbon
fold. First, it stops the punch from turning, steel and must have carbon added to achieve the
therefore keeping the correct alignment of the desired hardness. This is known as “case
exhaust hole to the routed die board. Secondly, it hardening.” The case is usually .003-.005 surface
keeps the punch tight in the die board which can hardened and about 58/60 Rockwell “C” scale.
loosen after a re-rule with an un-knurled punch. High carbon / tool steel punches can be neutral
hardened because the steel already contains carbon.
Pins: These punches are through hardened and work best
Pins are another method to keep a punch from at about 48/52 Rockwell.
turning in the die board. Most commonly, they are

R0
Guidelines On How To Order Punches
Essential Information:
The minimum required information needed when ordering a punch is quantity, height, cut size,
and style (i.e. side outlet, feed thru, tube, etc.).
Remember - The more thorough the information given, the less chance of any mistakes!
Additional Information:
1. What is the job that you are doing?

2. What kind of die are you using?
3. What type of material is being cut?
4. What are the quantity of pieces being cut?
5. Are you using a new or old die?
6. Do you want to keep the slug or the outside shape?
7. What type of press are you using?
8. What is the thickness of the dieboard?
9. Can you provide a sketch or print?
10. Is the shape mirrored?
11. Are there adhesives or liners?
12. Is the punch used for kiss cutting?
13. Can a print or file be sent via modem in .dxf format?
14. Are there any restrictions due to rule, other punches or spaces between cuts?
Helpful Hints:
When ordering standard punches it is best to use the supplier’s catalog along with their part number.
If possible FAX over the order, making sure to include all of the following information - your phone
number, fax number, person to contact, company name, date and purchase order number. Make sure
that all information is clear because faxes have been noted to blur information.
When sending a print, check to see that all of the dimensions are included on the print. Overwrite the
dimensions by hand if they are in small print and therefore likely to not be legible after faxing.
If the punches are being reordered, try to send the old packing slip.
When ordering, find a sales person who is competent and knowledgeable about their product and build
a relationship with that person. This way they will understand your operation and procedures so they can
lead you in the right direction. Do not be afraid to ask questions!! The manufacturer is there to help!
“Remember their best interest is your best interest”

R0
for
Punches
Punches - Tubular
Tolerance Tolerance
All Diameters Height +/- .002" +/- .051"
All Diameters Hardness* 45 to 60 45 to 60
3/16" - 3/4" Cutting Edge +/- .002" +/- .051 mm
Diameter
13/16" - 1-1/2" Cut Edge +/- .003" +/- .076 mm
Diameter
1 9/16" - 1-3/4" Cut Edge +/- .005" +/- .127 mm
Diameter
3/16" - ½" Concentricity +/- .003" +/- .076 mm
9/16" - 15/16" Concentricity +/- .004" +/- .102 mm
1" - 1-3/4" Concentricity +/- .006" +/- .152 mm
3/16" - ½" Base Size +.002" + .051 mm
Diameter - .000" - .000 mm
9/16" - 1-7/16" Base Size + .003" + .076 mm
Diameter - .000" - .000 mm
1-1/2" - 1-3/4" Base Size + .005" + .127 mm
Diameter - .000" - .000 mm
*Case Hardness Depth .003" to .005" (.076 mm to .127 mm).

3-5AR0
for
Punches
Punches - Feed-Thru
Tolerance Tolerance
All Diameters Height +/- .002" +/- .051"
3/16" - 3/4" Cutting Edge +/- .002" +/- .051 mm
Diameter
13/16" - 1-1/2" Cut Edge +/- .003" +/- .076 mm
Diameter
1 9/16" - 1-3/4" Cut Edge +/- .005" +/- .127 mm
Diameter
1-9/16" - 1-3/4" Concentricity +/- .008" +/- .203 mm
3/16" - ½" Base Size +.003" + .076 mm
Diameter - .000" - .000 mm
9/16" - 1-7/16" Base Size + .004" + .102 mm
Diameter -. 000" - .000 mm
1-1/2" - 1-3/4" Base Size + .005" + .127 mm
Diameter - .000" - .000 mm

3-6AR0
for
Punches
Punches - Cup
Tolerance Tolerance
All Diameters Height +/- .002" +/- .051 mm
All Diameters Cutting Edge +/- .002" +/- .051 mm
Diameter
All Diameters Concentricity +/- .003" +/- .076 mm
All Diameters Base Size + .002" + .051 mm
Diameter - .000" - .000 mm

3-7AR0
for
Punches
Punches - Serrated Tubular

Tolerance Tolerance
1/4" - ½" Cutting Edge +/- .002" +/- .051 mm
Diameter
9/16" - 1-3/4" Cutting Edge +/- .005" +/- .127 mm
Diameter
1/4" - ½" Base Size + .002" + .051 mm
Diameter - .000" - .000 mm
9/16" - 1-7/16" Base Size +.003" +.051 mm
Diameter - .000" - .000 mm
1-1/2" - 1-3/4" Base Size +.005" +.127 mm
Diameter - .000" - .000 mm

3-8AR0
for
Punches
Punches - Side Outlet

Tolerance Tolerance
Diameter
Diameter - .001" - .025 mm
All Diameters Base Size + .006" +.152 mm
Diameter to to
at Knurl .012" .305 mm

3-9AR0
for
Punches
Punches - Serrated Side Outlet

Tolerance Tolerance
All Diameters Height + .005" +.127 mm
- .000" - .000 mm
Diameter
Diameter - .001" - .025 mm
Diameter to to
at Knurl .012" .304 mm

3-10A
for
Punches
Punches - Oblong Side Outlet

Tolerance Tolerance
All Diameters Height + .001" + .002" Tolerances also
- .002" - .051 mm apply to any custom
shape punch
All Diameters Hardness* 47 to 56 47 to 56 Tolerances also

Rockwell C Scale Rockwell C Scale apply to any custom
shape punch
All Diameters Cutting Edge +/- .002" +/- .051 mm Tolerances also
Dimension apply to any custom
shape punch
All Diameters Base Size +/- .002" +/- .051 mm Tolerances also
Dimension apply to any custom
shape punch

3-11A
for
Punches
Punches - Squeezed or Formed Oval Tubular

Tolerance Tolerance
All Diameters Height +/- .002" +/- .051 mm Tolerances apply to
standard sizes only
All Diameters Hardness* 45 to 60 45 to 60 Tolerances apply to

Rockwell C Scale Rockwell C Scale standard sizes only
All Diameters Cutting Edge +/- .007" +/- .178 mm Tolerances apply to
Dimension standard sizes only
All Diameters Base Size Not Applicable Not Applicable Tolerances apply to

3-12A
for
Punches
Punches - Squeezed or Formed Oval Feed-Thru

Tolerance Tolerance
All Diameters Height +/- .002" +/- .051 mm Tolerances apply to
standard sizes only
All Diameters Hardness* 45 to 60 45 to 60 Tolerances apply to

Rockwell C Scale Rockwell C Scale standard sizes only
All Diameters Cutting Edge +/- .008" +/- .203 mm Tolerances apply to
All Diameters Base Size Not Applicable Not Applicable Tolerances apply to

3-13A
CHAPTER 4
COUNTER PLATES
General Information Regarding Counter Plates
Steel Counter Plates
Steel Counter Plates, also referred to as “Flush Counters,” are full size steel
plates with the creasing channels placed directly into the plate. With this type of
counter, the crease and knife action are almost on the same plane when the press
is on impression. This means that the diecut sheet is not subjected to excessive
stress and remains flat throughout the diecutting cycle.
With a steel counter plate system, there is less dust, loose fiber and flaking. Also,
the diecut sheet is far less likely to break apart. Therefore press speed is
maximized.
Steel counter plates are produced from the same CAD/CAM program as the die
to guarantee exact registration to the die.
Steel counter plates are currently manufactured by one of the following methods:
mechanically milled, chemically etched, or laser etched.
Steel counter plates are available both as full thickness and transfer type.

Note: This article reprinted from Wagner Supply Group Die-Gest
Written by James R. Barnes, Channel Creasing Matrix, Martinsburg, WV, USA
One of the properties of paper and machine travel and cross grain (CG), perpendicular
paperboard that makes it desirable is its ability to to the direction of machine travel.
accept a controlled fold in the middle of a stiff In creasing the paperboard, two basic
sheet. This is made possible through a process changes take place. The board must be partially
called creasing or scoring. delaminated and it must be permanently deformed.
Paperboard is produced from natural This is accomplished by bending the board at a
cellulose fibers found in trees. This is done by sufficiently sharp angle so that the delamination and
taking the fibers apart and then putting them back deformation occurs in the proper manner. The angle
together under controlled conditions. The principal required to do this depends on the elastic properties
methods used for taking the fibers apart are of the board. Here grain comes into play. Machine
chemical, which removes the organic binder direction, being more elastic, may require a deeper
between the fibers, and mechanical, which tears the rule penetration or a more narrow channel to
fibers apart physically. This pulping process achieve the sharper angle necessary to obtain
produces papers of varying characteristics with the equivalent deformation and delamination of the
mechanical process producing fibers which are board.
shorter and weaker. The best example of this is The delamination and deformation of the
newsprint. The fibers are then put back together to board results in a bead which permits folding to
form a fibrous mat that eventually becomes paper take place without rupturing the top liner. If this
plies. Individual plies are joined together to form bead is not sufficiently formed and is too near the
paperboard. During this process, various surface of the board, when the board is folded the
mechanical and chemical treatments are added to bead will act as a fulcrum and cause the top to
achieve the desired properties. rupture. Proper bead formation results in the fiber
Although much of the world’s paper is made being simply squeezed out of the way during
from virgin fiber, there is an increasing trend to folding.
produce recycled paper. Here the paper is made Board qualities and characteristics obviously
from fiber that once was carton, a newspaper or have a large effect on creasing. During creasing and
other paper product. This reprocessing produces folding the top layer is put under pressure and
shorter fibers which are not as strong as virgin stretched. It must be of sufficient strength to accept
fibers and consequently affects the physical the stress needed to delaminate the plies and force
properties. the filler into a bead. Keeping in mind that an MD
As a result of the manufacturing process, the crease stretches the board in cross machine
fibers of the paperboard tend to align themselves in direction, a CG crease stretches the board in
the direction the paper machine travels. This fiber machine direction, multiply paperboard will stretch
alignment is called grain and referred to as machine more in the cross machine direction.
direction (MD), fibers aligned in the direction of

Here the effect of moisture content comes into play. properties and the need to create a sharper angle to
Board processed under conditions of very low achieve equivalent deformation of the board. Here
humidity can cause creasing problems, because as rule height becomes vary important and MD creases
the humidity decreases, the ability to stretch may require slightly more rule penetration to form
decreases. Another area that is often overlooked is the proper bead.
ply bond strength. If it is too strong, you may have An example of the above can be illustrated
problems creasing. Here the selection of the board in the creasing of .024" board. Selection of a 2
manufacturer is important. Can he produce a board point (.028") crease rule and applying the formula
of good ply bond strength and yet one that will twice the board thickness plus the width of the
accept delamination when creased? creasing rule, will result in a channel width of
In the creasing of paperboard, there are .074"-.076" (2 x .024 + .028). This ratio of board
certain physical parameters that must be met in caliper to channel width of 3.2:1, which would be
order to produce a good crease. You should know satisfactory for a MD crease, but unsatisfactory for
what type of board you are working with, its a CG crease. Selection of a 3 point (.042") rule
characteristics, size and moisture content. Two of would require a channel width of .088" - .090" (2
the most important physical parameters are creasing x .024 + .042) and results in a ration of 3.7:1
rule selection, both width and height, and which would be satisfactory for both MD and CG
establishing a proper female counter or matrix. creases.
In selection of the proper creasing rule, Remember that in order for the board to fold
there are two major considerations and both relate properly, there must be a proper crease. A proper
to the female counter. First, the female counter or crease requires delamination and deformation of the
matrix should be approximately twice the board board. In order to do this you must establish the
caliper plus the width of the creasing rule. Second, correct relationship between the board caliper, rule
the female counter should have a width of 3-1/2 to thickness and height, and width of the female
4 times the board caliper, although this value may channel.
vary for MD scores because of the increased elastic

General Information Regarding Steel Counter Plates

for
Counter Plates
Counter Plates - Steel

Tolerance Tolerance
N/A Hardness 44 to 53 44 to 53
N/A Width +/- .015" +/- .380 mm
N/A Length +/- .015" +/- .380 mm
N/A Thickness +/- .002" +/- .051 mm
N/A Squareness +/- .0625" +/- 1.588 mm
(Sheared Edges)
N/A Squareness +/- .0313" +/- .794 mm
(Machined Edges)
N/A Parallelism +/- .002" +/- .051 mm
N/A Channel Width +/- .002" +/- .051 mm
N/A Channel Depth +/- .002" +/- .051 mm
N/A Alignment Hole +/- .001" +/- .025 mm
Diameter
Alignment Hole +/- .001" +/- .025 mm
Location

for
Steel Counter Channel Chart for Board Types:

Cylinder Board, Clay Coated News, Fourdrinier, S.B.S.
Channel GRAIN GRAIN GRAIN GRAIN
Caliper Depth WITH ACROSS WITH ACROSS WITH ACROSS WITH ACROSS
.012/.305 .014/.356 .045/1.14 .049/1.24 .054/1.37 .058/1.47 .068/1.73 .072/1.83

.013/.330 .015/.381 .047/1.19 .051/1.29 .056/1.42 .060/1.52 .070/1.78 .074/1.99
.014/.356 .016/.406 .049/1.24 .053/1.35 .058/1.47 .062/1.57 .072/1.83 .076/1.93
.015/.381 .018/.457 .051/1.29 .055/1.37 .060/1.52 .064/1.63 .074/1.88 .078/1.98
.016/.406 .019/.483 .053/1.35 .057/1.45 .062/1.57 .066/1.68 .076/1.93 .080/2.03
.017/.432 .020/.508 .064/1.63 .068/1.73 .078/1.98 .082/2.08
.018/.457 .021/.533 .066/1.68 .070/1.78 .080/2.03 .084/2.13
.019/.483 .022/.559 .068/1.73 .072/1.83 .082/2.08 .086/2.18
.020/.508 .023/.584 .070/1.78 .074/1.99 .084/2.13 .088/2.23
.021/.533 .024/.610 .072/1.83 .076/1.93 .086/2.18 .090/2.29
.022/.559 .025/.635 .074/1.88 .078/1.98 .088/2.23 .092/2.34
.023/.584 .027/.686 .076/1.93 .080/2.03 .090/2.29 .094/2.39
.024/.610 .028/.711 .078/1.98 .082/2.08 .092/2.34 .096/2.44
.025/.635 .029/.737 .080/2.03 .084/2.13 .094/2.39 .098/2.49
.026/.660 .030/.762 .082/2.08 .086/2.18 .096/2.44 .100/2.54
.027/.686 .032/.813 .084/2.13 .088/2.23 .098/2.49 .102/2.59
.028/.711 .033/.838 .086/2.18 .090/2.29 .100/2.54 .104/2.64 .114/2.90 .118/3.00
.029/.737 .034/.864 .088/2.23 .092/2.34 .102/2.59 .106/2.69 .116/2.95 .120/3.05
.030/.762 .035/.889 .090/2.29 .094/2.39 .104/2.64 .108/2.74 .118/3.00 .122/3.10
.031/.787 .036/.914 .092/2.34 .096/2.44 .106/2.69 .110/2.79 .120/3.05 .124/3.15
.032/.813 .037/.940 .094/2.39 .098/2.49 .108/2.74 .112/2.85 .122/3.10 .126/3.20
.033/.838 .038/.965 .096/2.44 .100/2.54 .110/2.79 .114/2.90 .124/3.15 .128/3.25
.034/.864 .039/.991 .098/2.49 .102/2.59 .112/2.84 .116/2.95 .126/3.20 .130/3.30
.035/.889 .040/1.02 .100/2.54 .104/2.64 .114/2.90 .118/3.00 .128/3.25 .132/3.35
.036/.914 .041/1.04 .102/2.59 .106/2.69 .116/2.95 .120/3.05 .130/3.30 .134/3.40
Notes:
# All dimensions are shown in inches/millimeters.
# Add .007"/.178mm to channel widths for those that have cuts in crease score channels (for 2 pt.
only)
# Suggested counter plate thickness for board caliper greater than .029"/.737mm is .060"/1.52mm

for
Steel Counter Channel Chart for Board Types:

Kraft Coated, Bottle Carrier Stock
Suggested 2-PT 3-PT 4-PT 6-PT

Board Channel GRAIN GRAIN GRAIN GRAIN
Caliper Depth WITH ACROSS WITH ACROSS WITH ACROSS WITH ACROSS
.012/.305 .014/.356 .048/1.22 .056/1.42 .062/1.57 .070/1.78

.013/.330 .015/.381 .050/1.27 .058/1.47 .064/1.63 .072/1.83
.014/.356 .016/.406 .052/1.32 .060/1.52 .066/1.68 .074/1.88
.015/.381 .018/.457 .054/1.37 .062/1.57 .068/1.73 .076/1.93
.016/.406 .019/.483 .056/1.42 .064/1.63 .070/1.78 .078/1.98
.017/.432 .020/.508 .058/1.47 .066/1.68 .072/1.83 .080/2.03
.018/.457 .021/.533 .060/1.52 .068/1.73 .074/1.88 .082/2.08
.019/.483 .022/.559 .062/1.57 .070/1.78 .076/1.93 .084/2.13
.020/.508 .023/.584 .064/1.63 .072/1.83 .078/1.98 .086/2.18
.021/.533 .024/.610 .066/1.68 .074/1.88 .080/2.03 .088/2.23
.022/559 .025/.635 .068/1.73 .076/1.93 .082/2.08 .090/2.29 .096/2.44 .104/2.64
.023/.584 .027/.686 .070/1.78 .078/1.98 .084/2.13 .092/2.34 .098/2.49 .106/2.69
.024/.610 .028/.711 .072/1.83 .080/2.03 .086/2.18 .094/2.39 .100/2.54 .108/2.74
.025/.635 .029/.737 .074/1.88 .082/2.08 .088/2.23 .096/2.44 .102/2.59 .110/2.79
.026/.660 .030/.762 .076/1.93 .084/2.13 .090/2.29 .098/2.49 .104/2.64 .112/2.85
.027/.686 .032/.813 .078/1.98 .086/2.18 .092/2.34 .100/2.54 .106/2.69 .114/2.90
.028/.711 .033/.838 .080/2.03 .088/2.23 .094/2.39 .102/2.59 .108/2.74 .116/2.95 .136/3.45 .144/3.66
.029/.737 .034/.864 .082/2.08 .090/2.29 .096/2.44 .104/2.64 .110/2.79 .118/3.00 .138/3.50 .146/3.71
.030/.762 .035/.889 .084/2.13 .092/2.34 .098/2.49 .106/2.69 .112/2.85 .120/3.05 .140/3.56 .148/3.76
.031/.787 .036/.914 .086/2.18 .094/2.39 .100/2.54 .108/2.74 .114/2.90 .122/3.10 .142/3.62 .150/3.81
.032/.813 .037/.940 .088/2.23 .096/2.44 .102/2.59 .110/2.79 .116/2.95 .124/3.15 .144/3.66 .152/3.86
.033/.838 .038/.965 .090/2.29 .098/2.49 .104/2.64 .112/2.85 .118/3.00 .126/3.20 .146/3.71 .154/3.91
.034/.864 .039/991 .092/2.34 .100/2.54 .106/2.69 .114/2.90 .120/3.05 .128/3.25 .148/3.76 .156/3.96
.035/.889 .040/1.02 .094/2.39 .102/2.59 .108/2.74 .116/2.95 .122/3.10 .130/3.30 .150/3.81 .158/4.01
.036/.914 .041/1.04 .096/2.44 .104/2.64 .110/2.79 .118/3.00 .124/3.15 .132/3.35 .152/3.86 .160/4.06
Notes:
# All dimensions are shown in inches/millimeters.
# Add .007"/.178mm to channel widths for those that have cuts in crease score channels (for 2
pt. only)
# Suggested counter plate thickness for board caliper greater than .029"/.737mm is
.060"/1.52mm

General Information Regarding Phenolic Counter Plates
Phenolic or Plastic Counter Plates are individual counters manufactured to match

each carton position of the die. These individual counters are positioned from the
die to the cutting plate with a pin registration system and adhered to the cutting
plate with adhesive. They might also be referred to as “Protruding Counters”
because, when fastened to the face of the cutting plate, the top surface of the
phenolic material “protrudes” above the plane formed by the tip of the cutting
knife when the press is closed on impression.
Phenolic counter plates are produced from the same CAD/CAM program as the
die to assure exact registration to the die.
Phenolic counter plates are manufactured to ±.002 (.051mm) tolerance on

channel width and depth.
To help eliminate any “ghosting” impression, the counters are manufactured with
special skived edges around the contour of the individual counter plate.
Phenolic counters are manufactured on a special milling/routing machine

designed especially for this particular application and referred to as a counter
cutter.
Adhesive backed phenolic counters are available or the diecutter may elect to use
double sided tape, or apply adhesive themselves.
Counter plate material is available in a large number of thicknesses to fulfill most

crease requirements.

General Information Regarding Phenolic Counter Plates

for
Plastic/Phenolic Counter Plates
Counter Plates - Plastic/Phenolic

Tolerance Tolerance
N/A Thickness +/- .001" +/- .025 mm
N/A Channel Width +/- .002" +/- .051 mm
N/A Channel Depth +/- 10% of +/- 10% of
Total Channel Total Channel
Depth Depth
Diameter
Location

for
Phenolic Counter Plates
Phenolic Counter Channel Chart
Board Channel Phenolic 1-PT 2-PT 3-PT 4-PT 6-PT
caliper Depth Thickness
W-G A-G W-G A-G W-G A-G W-G A-G W-G A-G
.012 .012 .017 .038 .042 .052 .056 .066 .070 .080 .084 .108 .112
.013 .013 .018 .040 .044 .054 .058 .068 .072 .082 .086 .110 .114
.014 .014 .019 .042 .046 .056 .060 .070 .074 .084 .088 .112 .116
.015 .015 .020 .044 .048 .058 .062 .072 .076 .086 .090 .114 .118
.016 .016 .021 .046 .050 .060 .064 .074 .078 .088 .092 .116 .120
.017 .017 .022 .048 .052 .062 .066 .076 .080 .090 .094 .118 .122
.018 .018 .023 .050 .054 .064 .068 .078 .082 .092 .096 .120 .124
.019 .019 .024 .052 .056 .066 .070 .080 .084 .094 .098 .122 .126
.020 .020 .025 .054 .058 .068 .072 .082 .086 .096 .100 .124 .128
.021 .021 .026 .056 .060 .070 .074 .084 .088 .098 .102 .126 .130
.022 .022 .027 .058 .062 .072 .076 .086 .090 .100 .104 .128 .132
.023 .023 .028 .060 .064 .074 .078 .088 .092 .102 .106 .130 .134
.024 .024 .029 .062 .066 .076 .080 .090 .094 .104 .108 .132 .136
.025 .025 .030 .064 .068 .078 .082 .092 .096 .106 .110 .134 .138
.026 .026 .031 .066 .070 .080 .084 .094 .098 .108 .112 .136 .140
.027 .027 .032 .068 .072 .082 .086 .096 .100 .110 .114 .138 .142
.028 .028 .033 .070 .074 .084 .088 .098 .102 .112 .116 .140 .144
.029 .029 .034 .072 .076 .086 .090 .100 .104 .114 .118 .142 .146
.030 .030 .035 .074 .078 .088 .092 .102 .106 .116 .120 .144 .148
.031 .031 .036 .076 .080 .090 .094 .104 .108 .118 .122 .146 .150
.032 .032 .037 .078 .082 .092 .096 .106 .110 .120 .124 .148 .152
.033 .033 .038 .080 .084 .094 .098 .108 .112 .122 .126 .150 .154
.034 .034 .039 .082 .086 .096 .100 .110 .114 .124 .128 .152 .156
.035 .035 .040 .084 .088 .098 .102 .112 .116 .126 .130 .154 .158
.036 .036 .041 .086 .090 .100 .104 .114 .118 .128 .132 .156 .160

Reduced Bead Creasing
There has been a change in mind set towards how If we use a standard die and counter set-up for say
we treat our environment, which has brought forth a .016" board stock on a Bobst type diecutter, the following
change in how we convert packaging products. The biggest old standards would apply. A cutting rule of .937" height
concern today from local to national government is the by 2pt thick with crease rule of .918" height by 2pt thick
proper use of landfills and what is disposed of within them. for the die. The phenolic counter would be .021" thick
From this standpoint, laws have been enacted to force the with .060" with grain and .064" against grain channels
use of post consumer waste or recycled materials such as leaving .005" at the bottom of each channel. The reduced
board stock. The second part of the ecology connection is bead standard would be as follows. Cutting rule stays the
the proper way we treat forestation of old growth trees. same, but the crease rule changes to 3pt on 2pt crease at a
Environmentalists have had great success in getting the ear height of .915", the counter thickness stays the same but
of local, reginal and state officials towards setting aside the channels become .050" with grain and .054" against
more and more lands that contain these prescious natural grain leaving .005" at the channel bottom, see diagram
resources. One of the offsprings of this movement is the (A). Because we are pulling the crease height back there is
growth in manufacturing recycled paperboards and moving room to trap the boardstock at the channel tops forcing
consumer products to be packaged in them. It became the more stretching of the board at each channel edge instead
environmentally correct thing to do as large corporations of from channel to channel like standard die counter
struggled with corporate images as the largest polluters of set-ups.
the environment. For whatever reason we are now This type of creasing can actually improve the
converting about 65 to 75 percent recycled paper in most cleanliness of the diecut part also. Traditional creasing
converting plants today. allows the board to be stretched from cut to crease and
As a result of this trend, a new learning curve was from crease to crease, meaning that while the cutting rule
created in how we treat this short fibered, more rigid is working to cut through the board, the crease rule is also
material. By rigid this mean less flexible. As a result of the aiding the cut to tear through the board instead of cleanly
recycling process, the fibers in these materials become cutting it. We see this as flaking and angel hair on the edge
shorter and shorter while having a smoother of the carton. If we trap the board from point to point at
circumference, which means bonding them together the creases, they do their job independently from the cut
becoms more difficult while offering the same benefits we rule, allowing for both better creases and cleaner cutting.
saw in virgin paperbaords. What this means to someone Also more of the internal fibers of the carton are being
who has to convert these boards into a carton is that it has delaminated with this type of set-up, which means that the
more of a tendency to resist folding or creasing. We see it top side pressure of the printed surface will be less
as a stiffer fold or cracking that occurs along the spine of susceptable to fracturing when folded or opened by today’s
the crease. In some instances, it may surface fracture while high speed gluing and product insertion equipement. While
in others it may explode in high-tension areas of the crease. this sounds strange in the case of recycled board, the
This has brought forth the advent of reduced bead creasing. smaller the creased line, the better the result with reduced
As people struggled to find an efficient way to bead creasing. Typically people say if we go bigger on the
handle the new characteristics of recycled materials, it soon crease line, we reduce the internal tension, but this end
became evident that the old time proven formulas that our result leads to other problems with product fit, lack of
fathers and grandfathers used were not as viable anymore. clean crisp edge of the carton and spongy folds and gluing
One of the best ways to overcome the cracking tendencies nightmares.
of the board is by stretching or delaminating it within each Whatever your thoughts on this subject, it warrants
crease channel. Reduced bead offers the ability to trap the a try in your facility. The enclosed chart is meant to be a
board at the top corners of the crease channels while starting point for most board stock types and not the final
stretching the layers of board aruond the radius of the solution. Testing of any new manufacturing process is
crease rule, thereby forcing the internal delamination of neccassary for optimal results. This process is starting to
more of the fibers leading to less tension when folding the show up more and more as people find the results to be
carton or design, with more flexibility of these channels. truly rewarding.
To create these channels requires the use of a larger
thickness of crease rule with less height and closing of the
counter channel width.

Reduced Bead Creasing
Diagram (A) Reduced Bead Die & Counter Side View
100 % Cutting = .937” Cut

A&B = .915” 3pt on 2pt Crease
Counter Plate = .021” Phenolic Counter .050” W/G Channel
Board Stock = .016”

for
Reduced Bead Phenolic Counter Plates
Phenolic Counter Channel Chart
Board Channel Phenolic 1-PT 2-PT 3-PT 4-PT
caliper Depth Thickness
W-G A-G W-G A-G W-G A-G W-G A-G
.012 .012 .017 .028 .032 .042 .046 .056 .060 .070 .074
.013 .013 .018 .030 .034 .044 .048 .058 .062 .072 .076
.014 .014 .019 .032 .036 .046 .050 .060 .064 .074 .078
.015 .015 .020 .034 .038 .048 .052 .062 .066 .076 .080
.016 .016 .021 .036 .040 .050 .054 .064 .068 .078 .082
.017 .017 .022 .038 .042 .052 .056 .066 .070 .080 .084
.018 .018 .023 .040 .044 .054 .058 .068 .072 .082 .086
.019 .019 .024 .042 .046 .056 .060 .070 .074 .084 .088
.020 .020 .025 .044 .048 .058 .062 .072 .076 .086 .090
.021 .021 .026 .046 .050 .060 .064 .074 .078 .088 .092
.022 .022 .027 .048 .052 .062 .066 .076 .080 .090 .094
.023 .023 .028 .050 .054 .064 .068 .078 .082 .092 .096
.024 .024 .029 .052 .056 .066 .070 .080 .084 .094 .098
.025 .025 .030 .054 .058 .068 .072 .082 .086 .096 .100
.026 .026 .031 .056 .060 .070 .074 .084 .088 .098 .102
.027 .027 .032 .058 .062 .072 .076 .086 .090 .100 .104
.028 .028 .033 .060 .064 .074 .078 .088 .092 .102 .106
.029 .029 .034 .062 .066 .076 .080 .090 .094 .104 .108
.030 .030 .035 .064 .068 .078 .082 .092 .096 .106 .110
.031 .031 .036 .066 .070 .080 .084 .094 .098 .108 .112
.032 .032 .037 .068 .072 .082 .086 .096 .100 .100 .114
.033 .033 .038 .070 .074 .084 .088 .098 .102 .112 .116
.034 .034 .039 .072 .076 .086 .090 .100 .104 .114 .118
.035 .035 .040 .074 .078 .088 .092 .102 .106 .116 .120
.036 .036 .041 .076 .080 .090 .094 .104 .108 .118 .122
IADD Recommended Specifications 4-11.3A R1

for
Reduced Bead Crease Rule Types
Rule Selection Chart
1 PT 2 PT 3 PT 4 PT
Board Channel Phenolic Channels Channels Channels Channels
caliper Depth Thickness Use 2 PT Use 3 on2 Use 4 on 2 Use 5 on 6
Crease Crease Crease Crease
.012 .012 .017 0.919 0.919 0.919 0.919
.013 .013 .018 0.918 0.918 0.918 0.918
.014 .014 .019 0.917 0.917 0.917 0.917
.015 .015 .020 0.916 0.916 0.916 0.916
.016 .016 .021 0.915 0.915 0.915 0.915
.017 .017 .022 0.914 0.914 0.914 0.914
.018 .018 .023 0.913 0.913 0.913 0.913
.019 .019 .024 0.912 0.912 0.912 0.912
.020 .020 .025 0.911 0.911 0.911 0.911
.021 .021 .026 0.910 0.910 0.910 0.910
.022 .022 .027 0.909 0.909 0.909 0.909
.023 .023 .028 0.908 0.908 0.908 0.908
.024 .024 .029 0.907 0.907 0.907 0.907
.025 .025 .030 0.906 0.906 0.906 0.906
.026 .026 .031 0.905 0.905 0.905 0.905
.027 .027 .032 0.904 0.904 0.904 0.904
.028 .028 .033 0.903 0.903 0.903 0.903
.029 .029 .034 0.902 0.902 0.902 0.902
.030 .030 .035 0.901 0.901 0.901 0.901
.031 .031 .036 0.900 0.900 0.900 0.900
.032 .032 .037 0.899 0.899 0.899 0.899
.033 .033 .038 0.898 0.898 0.898 0.898
.034 .034 .039 0.897 0.897 0.897 0.897
.035 .035 .040 0.896 0.896 0.896 0.896
.036 .036 .041 0.895 0.895 0.895 0.895

General Information Regarding Creasing Matrix
Creasing/Scoring Matrix Strips
Why Ready-Made Creasing/Scoring Matrix Strips 3. Height of the creasing rule -- The height of the
Makeready and preparation of a creasing/scoring matrix creasing/scoring rule relative to the cutting rule and
has traditionally been a time-consuming and expensive board thickness is also extremely important. Too much
operation. Ready-made matrix strips with uniform width impression on the paper stock or board can cause
and depth measurements insure far greater accuracy and excessive stretch of the top liner and rupture the sheet.
uniformity than hand-cut matrix. And since precise When using metal base creasing/scoring matrix, an
location of creasing/scoring matrix strips have been allowance of .009" should be made to compensate for
considered the most time-consuming factor in the metal and adhesive. No adjustment is normally
makeready, “self-locating” matrix strips can drastically necessary for mylar based creasing/scoring matrix.
cut your cost and time of makeready. With the “self-
locating” feature of ready-made matrix strips, the down EXAMPLE:
time barrier is now broken. Absolute accuracy of Metal base creasing/scoring matrix -- Subtract the
register is guaranteed and downtime is virtually thickness of the board from the height of the cutting
eliminated. rule, then subtract an additional .009"
Design of Ready-Made Creasing/Scoring Matrix For example, for .024" board:

Strips
1. Creasing/scoring matrix strips are available with Height of cutting Rule .937"
either a thin steel base or a thin mylar base. The height Less Thickness of board - .024"
of the creasing rule is dependent upon the base material .913"
on the strip. Less thickness of matrix base - .009"
2. A removable locator strip is attached to the matrix Equals height of cutting rule .904"
with easily removable pressure sensitive adhesive. This
assures that you will not accidentally remove the matrix Mylar base Creasing/scoring matrix -- Subtract the
when removing the locator. thickness of the board from the height of the cutting
rule.
3. Creasing/scoring matrix is securely adhered to the
cutting plate with adhesive which is on the base of the For example, for .024" board:
strip. There is no creeping or slipping through the
longest runs - yet the matrix is easily removed upon Height of cutting Rule .937"
completion. Less Thickness of board - .024"
Factors Affecting Good Makeready Equals height of cutting rule .913"

1. Cleanliness of the cutting jacket -- The cutting plate
or cylinder must be extremely clean and free from any 4. Thickness of the creasing/scoring rule
kind of grease, dust or moisture. NOTE: Do not use oil- A basic recommendation:
based cleaners! 2-pt. rule for boards up to .025"
3 pt. rule for boards up to .040"
2. Width of the female channel -- This is the most 4 pt. rule for boards up to .055"
important mechanical element in obtaining quality 6 pt. Rule for board up to .070"
creasing/scoring. As a rule, the width of the female
groove should be equal to the thickness of the 5. Depth of the channel in the matrix
creasing/scoring rule, plus twice the thickness of your The correct depth will assure longer life of the matrix
paper stock or board. and die as well as protect the stock board surface finish.
(Consult your suppliers chart for exact sizes)

E and F Flute Scoring
Suggested Application
Note: This Information provided by E & F Printing
Pico Rivera, CA, USA
 Scoring Rule - 3 point .905" high

E and F Flute when crushed = .030"
3 point rule height = .905"
.935"
Cutting Rule Height (.937 - .935" ) = .002" Clearance

(Rule height may vary slightly depending on your special circumstances.)
 Matrix (size) .039" x .106"

E and F Flute when crushed = .030" x 2 = .060"
3 point score width = .042"
.102"
Matrix width (.105" - .102") = (Clearance) = .004"
(Note: If steel based matrix is used, .900" rule would be appropriate.)
During makeready, on press, cutting rule must be carefully leveled using tape on the
backside of the dieboard, or a spot sheet, placed under the cutting plate.
If overall impression is too hard, the cutting rule will flatten and allow too much
pressure on the cutting rule.
Rule of thumb for leveling of the die and impression: Bring the overall impression
of the cutting up to the point that approximately 80% of the die is cutting. Then
level the rest of the cutting by using tape on the back of the cutting rule or on a spot
sheet under the cutting plate.

for
Creasing Matrix
Creasing Matrix
Tolerance Tolerance
N/A Thickness +/- 10% of +/- 10% of
Total Thickness Total Thickness
Up to 120" Channel Width +/- .002" +/- .051 mm
Over 120" Channel Width +/- .005" +/- .127 mm
N/A Channel Depth +/- .002" +/- .051 mm
N/A Locator to +/- .002" +/- .051 mm
Channel

CHAPTER 5
CUTTING PLATES
General Information Regarding Cutting Plates
The cutting plate of the diecutting machine is a highly accurate

ground steel plate for “kiss cut” cutting the diecut product. This is
one of the most important factors in successful diecutting. Its
accuracy, along with a proper balanced cutting die and makeready,
will assure maximum production.

R0
for
Hard Cutting Plates
Hard Cutting Plates

Tolerance Tolerance
N/A Width +/- .008" +/- .203 mm
N/A Length +/- .008" +/- .203 mm
N/A Thickness +/- .002" +/- .051 mm
N/A Squareness* +/- .0625" +/- 1.588 mm
(Sheared Edges)
N/A Squareness* +/- .0313" +/- .794 mm
(Machined Edges)
Under Parallelism +/- .0015" +/- .038 mm
42" / 1.067 m
Over Parallelism +/- .002" +/- .051 mm
42" / 1.067 m
N/A Surface 18 to 32 RMS 18 to 32 RMS
Smoothness
*Measured on Diagonal

5-2AR0
CHAPTER 6
CHASE BACK PLATES
General Information Regarding Chase Back Plates
When diecutting, the chase back plate is a structural part

of the die chase which is made of a metal sheet that is slightly
softer than the cutting plate. This difference allows the back of
the rule to be driven into the plate, thereby protecting the
cutting edge of the rule in areas where there may be excessive
pressure. As continuous pounding of the rule into the plate
creates marks in the plate, the plate must periodically be honed
flat to remove these marks. This will help keep future dies flat
in the press.
In addition to protecting the cutting edge of the rule, the

chase back plate stiffens the chase frame to effectively hold the
steel rule die within the chase. It also provides a means to
“lock up” a die by applying pressure the die edge. Further, the
chase back plate is provided with a pattern of bolt holes for
securing the die to the chase with bolts.

R0
for
Backup (Backer) Plates
Backup (Backer) Plates

Tolerance Tolerance
N/A Width +/- .015" +/- .381 mm
N/A Length +/- .015" +/- .381 mm
N/A Thickness +/- .002" +/- .051 mm
N/A Squareness* +/- .0625" +/- 1.588 mm
(Sheared Edges)
N/A Squareness* +/- .0313" +/- .794 mm
(Machined Edges)
Under Parallelism +/- .0015" +/- .038 mm
42" / 1.067 m
Over Parallelism +/- .002" +/- .051 mm
42" / 1.067 m
*Measured on Diagonal

6-2AR0
CHAPTER 7
EJECTION MATERIAL
General Information Regarding Ejection Material
The Role of Ejection in Diecutting
Note: This material has been edited, condensed and reprinted from
Packaging Productivity Vol.1 No.1, March, 1992.
What does Ejection Material do in the

Diecutting Process? 5. The ejection material must have sufficient
The answer is that the ejection material performs density to prevent skewing before and after
three main functions during each diecutting cycle. pressure holding the material to be diecut.
These are: Pressure Hold, Compression Hold,
6. The ejection material must provide an even
and Pressure Eject
balance of pressure to enhance rather than
inhibit the performance of the diecutter.
Pressure Hold
Immediately prior to the die coming in contact with
Compression Hold
the paperboard sheet, the ejection material pinches
Under compression, the ejection material minimizes
and holds the sheet of paperboard in position to
the forces caused by the diecutting process in
prevent distortion as the cutting process begins.
breaking apart the diecut sheet and prevents
To fulfill the first of its three primary
material distortion.
functions, ejection materials must provide 6 key
To fulfill the second of its three primary
abilities:
functions, ejection materials must provide 3 key
abilities:
1. The ejection material must provide sufficient
clearance above the tool to clamp the material
1. The ejection material must hold the diecut
to be diecut prior to machining.
sheet securely, restricting the degree of
movement caused by the lateral forces
2. The ejection surface must be level and flat so
emanating from action of the die and counter
holding pressure is applied simultaneously.
tools.
resistance to compression to hold the material
sheet securely, with sufficient force to prevent
to be diecut securely but not so much resistance
diecut sheet break-up, but with insufficient
as to inhibit or restrict the ability of the tool
force to cause material/product damage.
press to function efficiently.
sheet securely, preventing lateral forces
resistance to compression to hold the material
breaking the diecut sheet apart and separating
securely but not so much resistance to damage
the nicks, as the tools withdraw.
or distort the diecut material/product.

R0
The Role of Ejection in Diecutting
Pressure Eject
As the lower platen retracts from the machine cycle, 4. The ejection material must have the ability to
the ejection material holds the diecut sheet until the provide variable densities and durometers to
die is clear and releases or “ejects” the diecut sheet support different levels of ejection force in
from transportation to the next unit. response to design shape and size.
To fulfill the third of its three primary
functions, ejection materials must provide 6 key 5. The ejection material must have a smooth level
abilities: support surface to ensure pressure is distributed
evenly and at right angles to the applied force.
1. The ejection material must maintain control of
multiple, linked pieces of product and waste as 6. The ejection material must provide the ability
the paperboard is ejected/released from the die. to withstand repeatable compression and
recover each time at high speed.
2. The ejection material must provide the ability
to eject/release multiple pieces of linked diecut This description of the three key functions of
material evenly from the die preventing sheet ejection,
break-up.
! Pressure Hold
3. The ejection material must provide the ability ! Compression Hold
to eject the diecut sheet at high speed and
recover ready for the next press cycle. ! Pressure Eject
form the foundation of ejection design, material
selection, and specification procedures.

R0
Ejection Sponge: “The Important 16th”
Note: This article has been reprinted from IADD’s The Cutting Edge.
Written by Roger Brown, Sales Manager, Monroe Rubber & Plastic, Inc., Monroe, MI, USA
The art of “corking” or “rubbering” a die often overlooked. In flat diemaking, die ejection
is, at long last, receiving its just attention in material that is 1/16" over rule height is necessary
diecutting plants around the country. Just about to lift the cut part off of the cutting surface in order
everything else about a die has been under a for the sheet to move out of the press cutting section
microscope to better understand how to make swiftly and cleanly. During the diecutting process,
diecutting work more efficiently. the ejection material is compressed and relaxed so
Dieboards have been subjected to computer many times that it tends to become worn down, and
jigging and laser cutting, in addition to wood being it takes a “compression set.” To compensate for
substituted for other materials, including steel. this condition, about 1/16" in additional height is
Diecutters have never had such a selection of required for the life of the diecutting run.
steel rule to choose from as they do now. Rules The other element of the important 1/16" is
from all points of the globe that are ground, skived, the placement of the ejection material 1/16" away
softened, edge hardened, coated and beveled to an from the cutting knife. As the ejection sponge is
unheard of multitude of angles are presently compressed, it deflects into the adjacent knife,
available. In addition, diemakers can bend these which will cause friction at the least and could bend
rules manually, pneumatically, or with new over the knife, break miters, or by continual knife
automatic rule processors. In addition, rule wriggle, widen the kerf. By placing the sponge
dimensions are held to tolerances heretofore 1/16" away from the knife, the sponge will work
reserved by NASA. With all of this attention given freely and, in addition to not causing the above
to the die, what about the ejection material and its problems, the press can work with less impression
placement on the die? and the substrate will cut more easily and cleanly.
Nothing can slow down a press faster or
mess up diecutting as much as the improper *For metric users, “The important 1.5 Rule,” or
placement or use of the ejection material. While 1.5mm.
much can be said about die ejection material, the
importance of the 1/16*, or 1/16" to be specific, is

R0
Monroe’s E-Z SetTM Speeds Die Rubbering!
Note: This article was written by Roger Brown, Sales Manager, Monroe Rubber & Plastic, Inc.,
published in Die-GestTM newsletter by The Wagner Supply Group, (Vol.2, No.3).
Reprinted with permission.
The Problem: How to improve both speed and Viewed on end, the E-Z Set shape looks like
accuracy in die rubbering. a triangle with its pointed top cut off. When a
diemaker places the wide base of the E-Z Set strip
The solution: E-Z SetTM - a trapezoidal-shaped die against the exposed rule, the top of the sponge is
ejection sponge that helps a diemaker rubber a die automatically spaced the required distance from the
more quickly, more accurately and with greater rule. It’s fool-proof. And it means there will be no
consistency. crowding of sponge and rule in use; the shape allows
E-Z Set sponge ends the difficulty diemakers the body of the sponge to work freely -- away from
face in achieving a clearance of 1/16" between the the rule -- even under maximum compression.
sponge and the rule. With conventionally shaped With 50% to 70% of a die cost contributed by
sponge, this requires time consuming measurements labor, E-Z Set sponge offers significant opportunity
along the gap between rule and sponge. When to reduce costs, A diemaker can place E-Z Set sponge
compressed, sponge that is too close to the rule may faster and more accurately than he can using
contact the rule as it deflects. This contact causes conventional material; no measuring is needed, yet
friction and heat that can wear sponge out accuracy is assured.
prematurely. Worse, it can deflect or deform the rule, MRP offers the E-Z Set shape in 1/4", 5/16"
break out miters, overwork a press and reduce the and 3/8" high strips of all their open cell materials,
sponge’s ejection ability. E-Z Set sponge eliminates plus Superject,TM G-Force,TM and rubberized cork.
undesirable contact between rule and sponge, thanks
to its unique shape.

R0
Thermoplastic Ejection Rubber
Note: This article was provided by the Shreiner Company, Killbuck, OH, USA
The drawback of open cell sponge rubber, Thermoplastic rubber is a linear polymer structure in
which is the most common ejection rubber used on which molecules form long chains of monomers.
flat dies, is the movement of air in and out of the These chemical reactions, or linking of organic or
open cells (see illustration). This air movement inorganic substances, create quicker reacting rubber
causes the material to dry out and deteriorate over action, or "bounce". This quicker reaction allows for
time. Each time the press opens and closes it is faster press speeds in platen die cutting. The
actually fracturing these cells as well, adding to the molecular structure of thermoplastic does not allow
short life span of the ejection rubber. For many short air to penetrate its surface and the press will not
runs, this ejection rubber performs adequately to get fracture the cells. In simulated flatbed die cutting
the job done. But, in cases where over 300,000 sheets tests of one and a half million impressions,
are required, thermoplastic rubber is a viable thermoplastic ejection rubber remained exact in
alternative. dimensions and shore hardness. In the field,
thermoplastic ejection rubber has endured over two
and a quarter million impression and has outlasted
the cutting rule on the die several times over.
Thermoplastic ejection rubber is most
commonly extruded into profile shapes and provided
in lengths or cut pieces.
Open Cell Rubber
Thermoplastic
IADD Product Information 7-4.1 7-4

R1
Band Saw Tip
Note: This article has been edited and reprinted from Packaging Productivity Vol.1 No.3, July, 1992.
It is now accepted discipline to space By building a simple plywood jig with an

ejection material away from the cutting edge of a adjustable side gauge that fits into the cross slide of
nicked steel rule knife to reduce compression the band saw table, we can cut strips of ejection
distortion and release forces pulling the diecut material to precise widths. However, when we
paperboard apart. The lateral force resulting from adjust the band saw table to give an angle cut we
the rubber being trapped against the side of the can now cut the ejection materials with an angle
knife also contributes to dust, loose fiber, and profile. By cutting a strip from the sheet of ejection
flaking, as the paperboard is ruptured before the material and flipping the material over for the next
cutting action is finalized. (See May 92 Packaging cut we can produce precisely angled ejection strips
Productivity). Therefore, all ejection material to any width.
should be spaced a precise distance from the knife The system of rubbering requires sheets of
edge, based upon the type ejection material being various durometers and heights of the ejection
used and the caliper of the material to be diecut. material to be purchased. Strips of ejection material
The acceptance of these principals saw the can be quickly produced with the spacing from the
introduction and proliferation of specially designed rule precisely controlled by setting a specific angle
ejection materials. Although these specialized on the band saw blade.
materials are effective, they are expensive and are The band saw can also be used to cut
of too high a durometer to be used throughout the batches of material to length and to bevel the
steel rule die. The difficulty of cutting and spacing ejection material for specialized applications and to
the balance of ejection materials throughout the reduce shadowing.
steel rule die results in tools poorly prepared for
dust free diecutting. Conclusion
Using this simple and inexpensive tool we can cut
The Solution ejection materials to provide precise spacing from
Ejection materials can be purchased in sheet form in the cutting edge. We can improve the preparation
a wide variety of durometers and compositions. To and consistency of pre-cut ejection material, speed
use this material for every type of ejection up the process, remove the need for specialized
application and to provide a simple and consistent adhesives, and we can reduce the cost of the entire
method of precisely spacing the ejection material ejection process. However, the bottom line is, we
from the knife edge only requires the use of an will improve the performance of diecutting and the
inexpensive woodworking tool, the band saw. quality of the diecut product.

R0
Ejection Material -- Width vs. Height
Note: Edited and reprinted from Packaging Productivity Vol.2 No.1, March, 1993
Question: I was told the width and the height of rubber should be the same.
Answer: The reason behind this guideline is

to ensure stability in rubbering. If the width of the
rubber is less than its height, it has a tendency to flex
away from the impressional force.
See illustration 1
Therefore to prevent movement and to stabilize the

rubber under pressure, the height and the width of the
rubber are approximately the same.
See illustration 2
However, if you need stability but not the amount of

impressional resistance, the full width would
generate, use a bandsaw to cut the sheets into tapered
strips. See illustration 3
This has the advantage of providing stability and

spaces the rubber consistently and accurately from
the knife. See illustration 4

R0
for
Ejection Material
Ejection Material - Closed Cell Sponge

Tolerance Tolerance
Soft Density* 2 - 5lbs. 1 - 2.25kg
Medium Density* 6 - 9lbs. 2.75 - 4kg
Medium Firm Density* 10 - 15lbs. 4.5 - 7kg
1/16" - 3/16" Thickness +/- .015" +/- .380mm
3/16" - 3/8" Thickness +/- .030" +/- .760mm
3/8" 5/8" Thickness +/- .040" +/- 1.00mm
(9.50mm)
over 5/8" Thickness +/- .060" +/- 1.50mm
*Density is the weight per cubic foot of the material being measured
NOTE: The ejection force (deflection), another measure of ejection material, is the force
measured in pounds per square inch (psi) that is developed by compressing the ejection material.
Most ejection material manufacturers make available the ejection force of their materials at 25%
compression.
Because of the wide varieties of ejection materials available in the market, it is impossible to
provide this information in these charts. The IADD suggests you contact your supplier for this
information.

7-7AR0
for
Ejection Material
Ejection Material - Open Cell Sponge

Tolerance Tolerance
Soft Density* 2 - 5lbs. 1 - 2.25kg
Medium Density* 6 - 9lbs. 2.75 - 4kg
Medium Firm Density* 10 - 15lbs. 4.5 - 7kg
Firm Density* 16 - 22lbs. 7.25 - 10kg
Extra Firm Density* Over 22lbs. Over 10kg
1/16" - 3/16" Thickness +/- .015" +/- .380mm
3/16" - 3/8" Thickness +/- .030" +/- .760mm
3/8" 5/8" Thickness +/- .040" +/- 1.00mm
(9.50mm)
over 5/8" Thickness +/- .060" +/- 1.50mm
measured in pounds per square inch (psi) that is developed by compressing the ejection
material.
Most ejection material manufacturers make available the ejection force of their materials at
25% compression.
Because of the wide varieties of ejection materials available in the market, it is impossible
to provide this information in these charts. The IADD suggests you contact your supplier
for this information.

7-8AR0
for
Ejection Material
Ejection Material - Cork or Cork/Rubber

Tolerance Tolerance
N/A Density* 40 Durometer 40 Durometer
+/- 5 +/- 5
(Shore A) (Shore A)
N/A Thickness +/- .015" +/- .380 mm
Ejection Material - Pure Gum Rubber

Tolerance Tolerance
N/A Density* 35 Durometer 35 Durometer
+/- 5 +/- 5
(Shore A) (Shore A)
N/A Thickness +/- .015" +/- .380 mm
measured in pounds per square inch (psi) that is developed by compressing the ejection material.
Most ejection material manufacturers make available the ejection force of their materials at 25%
compression.
Because of the wide varieties of ejection materials available in the market, it is impossible to
provide this information in these charts. The IADD suggests you contact your supplier for this
information.

7-9AR0
CHAPTER 8
DIEBOARD
General Information Regarding Dieboard
The Care & Feeding of Plywood

Note: This article has been adapted from Die-GestTM newsletter
published by Wagner Supply Group, (Vol.1, No.2).
The following suggestions are offered to help simply means we do not want the plywood laying
eliminate warpage in plywood. What we want to on the floor, leaning against a wall or leaning
accomplish is to eliminate parts of the plywood against another piece of plywood
being exposed to varying levels of moisture. This
Store plywood (banded) off the floor and

away from sidewalls. Place stacks of
plywood on 4 x 4's which are sufficient to
keep plywood off the floor and still allow air
to circulate.
Do not begin using new plywood right away.

Let the boards become acclimated to their
new environment for about one week.
If you buy plywood one or two sheets at a

time, do not stack them against a wall, on a
shelf, or directly on the floor. If possible,
suspend each board vertically off the floor or
place the boards on 4 x 4's or a pallet with
spacers between sheets.
There are also commercial storage systems

available that you may consider as a means
of storing plywood and finished dieboards.

8-1.0
Dieboard Storage
You spend a lot on your dieboards, it pays to store them right
Note: This article has been adapted from Die-GestTM newsletter
published by Wagner Supply Group, (Vol.1, No.2).
Considering the investment in laser cut tooling and the importance of optimal performance when the tool is used
and reused, it is critical to store steel rule dieboards effectively. The problem is how do we store dieboard in
such a way they are accessible and yet protected from warping, cupping, and twisting?
Flat Storage Suspended Storage

The traditional approach, a legacy of the multi-piece The most effective method of storing multiple sized
block dieboard era, was to store the dieboard flat on dieboards is to suspend then in a standard racking
retractable wood shelves in a rack. Although this is component using pins inserted through holes laser
convenient when used with an effective record cut into the dieboard. This has the advantage of
location system, the dieboard had one surface easy dieboard insertion and removal, the ability to
protected from changes in moisture levels and one handle any dieboard size, and the exposure of all
surface exposed. The result was the board would surfaces to the atmosphere ensures balanced
generally warp upward as the upper layers of the moisture levels and board flatness. (See illustration 4).
board dried out, or lost moisture. (See illustration 1).
Vertica l
Storage
The most common approach requires storing
dieboard vertically in a rack. The problem in
storing the board vertical was the great variety in
board sizes made the use of the upper and lower
track inconvenient and the results were usually
where multiple dieboards are stored leaning against
each other to ensure consistent warping and
damage! (See illustrations 2 & 3).

8-2.0
How to Keep Your Dieboards from Doing the Twist
Note: Article by Jim Wisun, Prairie Oak Communications, Inc.for IADD’s The Cutting Edge October 1996.
As the days grow shorter, you will allow the boards to

you know it’s only a matter of time adjust to the environment in
until the temperature drops, the your company’s storage area.
furnace kicks on at your shop and “Keep the crate strapped for at
your dieboards begin to warp. least five or six days,” says
Aggravation ensues as the heating Norman Roberts, president of
source changes the plywood by Die-Boards, Inc. in Brent-
creating moisture-level variations wood, NY, USA.
between the face and the back of Clement says, “Far and
the dieboard. away, the people who have the
By planning ahead, the fewest problems with warping
change of seasons doesn’t have to are those who let the shipment
mean new operational headaches sit when it reaches their
and exasperated phone calls to shop.”
dieboard suppliers. Here is how the experts
recommend you control dieboard and finished die The Technologies
warp and minimize downtime caused by the cupping Some dieboard suppliers recommend coating
or twisting of plywood. the edges, which are primary conduits for the
absorption of release of moisture. Others
The Ideal recommend coating the entire surface of the
“Ideally, what you want to do is store the plywood to crate a total moisture barrier that
boards in constant humidity,” say Bill Clement, increases the likelihood of a flat board. Coating, of
general manager of The Rayner Co. in Chicago, IL, course, is extra work and extra cost -- and
USA. “Companies that can store dieboards in a depending upon the product used, it may offend
climate-controlled enclosure that maintains relative your employees sense of smell.
humidity between 40 and 45 percent will have the “Some companies impregnate the dieboard
fewest problems with warping,” Clement says. with sealer, then pull a vacuum on the material to
draw the sealer into the pores of the board,” says
The Real World Tom Lenderink, president Lenderink, Inc. in
Few companies can afford the hermetically Belmont, MI, USA.
sealed approach, but several other proven methods Another new approach, according to
are available for reducing dieboard warp. Lenderink, is to use dieboards manufactured with a
new dry, laser-compatible glue developed by
The Waiting Game Eastman Kodak. “This prevents warping because no
moisture is added in the gluing process,” Lenderink
If your organization can wait at least five
says.
days before opening any new shipment of boards,

8-3.0
How to Keep Your Dieboards from Doing the Twist
“Gaining popularity are dieboards made temperature or moisture, and provide a thin
through the radio-frequency curing the process,” plywood cover sheet or similar cover to protect the
says Gene Piette, owner of Eugene C. Piette, a top board from absorbing or emitting moisture.
Westmont, IL, USA distributor. The process Mark Baril of Baril Steel Rule Die Co. Inc.,
removes moisture by cooking the panels from the Haverhill MA, USA says his company covers the
inside out -- in the same manner as a microwave, dieboard stack with a plastic tarp to guard the
according to Piette. plywood from the influence of moisture. The
Some companies have opted for synthetic customer must do the same for the finished tool.
dieboard that costs four to five times as much as Some companies, however, store their
standard maple plywood. “But not every customer dieboards vertically in racks. Pins inserted in the
will pay for a premium such as Permaplex,” says end of the dieboard suspend the wood in the rack,
Doug Conly, sales manager for EHV Wiedmann which virtually eliminates unbalanced exposure to
Industries, Inc. In St. Johnsbury, VT, USA. moisture according to The Diemaker’s Resource.
“Permaplex, a cellulose composite material,
fills a niche for diecutters who need a product with The Ultimate Solution — There is none, yet.
twice the density of maple and the ability to Your company’s geographic location will
withstand long-run applications and tight have a significant effect on what works best for
tolerances,” Conley says. The Permaplex product eliminating warp. “It’s a different problem in New
line has been expanded to include its Platinum England or Michigan or Southern California or
boards that feature sealer and acrylic for greater Florida,” Roberts says. Some firms may need to rig
resistance to moisture. humidifiers in their storage facilities. Because of
“Another technological innovation that’s vastly different climate conditions, others may
emerging is the use of South American maple, a require dehumidifiers.
variety that is harder than its North American Part of the challenge is identifying what
cousin,” Lenderink says. The South American qualifies as warp. IADD members have met
maple is cut in thinner plies -- such as 1/16 periodically to address the question of acceptable
(.158cm) -- that add greater reinforcement against warp tolerance. “There’s just never been a
warpage. consensus as to what is acceptable,” Clement says
How ever warp is ultimately defined, the
The Stack or The Rack question of how to best control it, remains open.
“Several anti-warp storage strategies can Roberts says, “It’s an issue on which we
protect your inventory of dieboards and dies,” need to get together the manufacturers, distributors,
according to Jim Anderson of Anderson and end users for a discussion.”
International Trading in Anaheim, CA, USA. Store
all panels flat, protect dieboards from extreme

8-4.0
General Information Regarding Laser Cutting
The 10 Most Frequently Asked
Questions About Laser Dieboard Cutting
Prepared by Laser Machining, Inc., Somerset, WI.
1. Is a laser system easy to operate? position of the beam’s focal point. If the focal point is
Yes. Lasers, beam delivery components, and too high, it will loosen the slot, and if too low, it will
motion controls are all easy to use. In addition, a laser tighten the slot. The focal point is maintained
diecutting system has the flexibility to cut many other consistently throughout the entire cutting area by an auto
materials. The system is simple to set up and only a few focus assembly. It has a contact foot that rides on the
adjustments are required from job to job. The laser itself board's surface and adjusts the focus as the beam cuts.
has a quick start up and shut down procedure. Operators The ability to control the focus height with the auto
place the board onto the work support, move the table to focus assembly is also important due to the
the start position and push the button. The controller inconsistencies in wood. The focus height may need to
does the rest. be changed if you are cutting with or against the grain
The most common form of controller is a of the wood. The focus also needs to be adjusted when
machine tool CNC (computer numeric control). As a changing from 2 to 3 point.
less expensive alternative, personal computers (PCS) are The quality of the bottom half of the slot is
now being programmed with CNC capability. Machine controlled by matching the speed of the table with the
operators do not need to be proficient in computer power in the beam. If the table is traveling slowly and
programming. Your existing drawing system can be the laser power is not adjusted, the bottom of the slot
used or a CAD package specifically for die cutting can will be too wide. If the table is traveling faster, the slot
be provided with your laser system. The CAD or other will be too narrow or not cut all the way through unless
drawing programs are translated into “G-code” before the laser power is increased. The speed and power need
being loaded into the controller. to be adjusted also as the system cuts varying slot
widths.
2. How is a quality slot achieved?
In laser dieboard cutting, the laser beam 3. Will my laser die board cutter need to be changed
diameter and shape determines the slot (kerf) quality in manually each time I change from 2 to 3 point or will
the board. That makes the laser beam the most it change automatically “on the fly?”
important factor in achieving perpendicular slots that are Both types of systems are available on the
not too loose or too tight. market today. What is required to make this change is
To maintain slot perpendicularity, the laser an adjustment in the focal height and the feedrate. Many
beam must be at right angles (perpendicular) to the laser systems do not offer an automatic system that will
board. The beam delivery must be adjustable so you can adjust “on the fly” from 2 to 3 point cuts.
change the angle of the incoming beam. Any two of the
following three features are essential to adjust the beam 4. Must I program in each bridge or is bridging
properly: an adjustable beam bender or corner block, an achieved automatically through the software?
XY adjustable lens, and an XY adjustable nozzle. Once There are many software programs available
the beam perpendicularity is set up, it should require that will place each bridge in automatically.
very few adjustments.
The quality of the top half of the slot is controlled by the

8-5.0
General Information Regarding Laser Cutting
The 10 Most Frequently Asked
Questions About Laser Dieboard Cutting
5. How is positional accuracy maintained? through the board, it would be reflected and would
Most positioning systems are constructed with scorch the back of the dieboard. Standoffs lower the
linear guides and ball screws mounted on a frame. The possibility that the beam will scorch the dieboard.
drive motors rotate a given amount to move the table in 2. This “stand off” also provides an area under
a linear direction and encoders feed back the table's the die board for the smoke and fumes to be “trapped”
position to the controller. The linear accuracy and and exhausted away from the work area.
repeatability of the table is dependent on the type of
encoder system, the quality of the linear motion 8. Is there any detection or protection for a beam
components, and the alignment of these components. delivery crash?
Not all systems have crash protection. In the
6. What happens to the fumes from cutting the event of a beam delivery crash, extensive damage to the
board? beam delivery and drive motors could result creating
Most systems provide a vacuum table/work costly repairs and down time.
support that will draw smoke and fumes from beneath Some systems have crash switches mounted on
the board. An exhaust hose is also located above the the beam delivery that will automatically shut down a
board to collect smoke and fumes from the top of the system in the event of a crash while cutting. The
board. This insures that most fumes are exhausted positioning system will stop, the laser shutter will close,
properly from the work area. and an alarm will appear on the controller screen.
7. How are the dieboards fastened to the table? 9. What warranty is available on most systems?
Dieboards are placed on a work support, Most laser systems come with a one-year (or
specifically a vacuum box, that is mounted on the XY 2000 operating hours, whichever comes first) warranty
table. The boards are secured to the work support either on all parts and labor. The beam delivery components
by manually actuated or by pneumatically actuated and the X Y table come with a 90 day warranty. Many
clamping devices. The advantage of the pneumatic system integrators look to the manufacturer of the laser
devices is the ease with which a rapid changeover can be to provide laser support.
achieved by the operator. Service may come from two separate sources if
On most work supports, the board is held up off the integrator's service people are not fully trained on
of the base of the work support by “stand offs.” These the laser.
can hold the work piece anywhere from 4" to 8" above
the base of the work support. This “stand off” has 2 10. What training and service are available?
functions: Training is recommended for all new systems.
1. The laser beam, after cutting through the The details of training and service vary from
board, still has some energy. If the board were to be cut manufacturer to manufacturer.
while on a flat, solid surface, once the beam made it

8-6.0
General Information Regarding Flat Maple Dieboards
Flat Maple Dieboards
Wood Species --
Predominately manufactured of Maple with as much as 30% of other hardwood
species which have physical characteristics comparable to Hard Maple.
Surface Finish --
Face --Sanded smooth - no voids.
Back -- Sanded smooth - no voids.
Delamination or Bubbling --
NOT ACCEPTABLE
Veneer Specifications --
Face -- Rotary cut, smooth, tight cut, full length
Face -- Acceptable defects:
Uniform light color variations
Scattered mineral streaks not to exceed 1/8"/3.2mm wide x 2"/51mm long
Sound pin knots diameter 1/8"/3.2mm or less
Scattered light bird’s-eye
Small tight burls 1"/25mm or less
Face -- Unacceptable defects:
Holes, voids, splits
Open joints or cracks
Foreign particles
Dark color variations including heartwood
Sound knots larger than 1/8"/3.2mm in diameter
Heavy bird’s-eye
Burls over 1" or cracked
Inner Plies -- Unacceptable defects:
More than 4 small (under 3/4"/19mm) holes per ply
Holes exceeding 3/4"/19mm in diameter
Interior cracks or splits exceeding 1/8"/3.2mm wide x 2"/51mm long
Burls or cross grain that will break across the length of the grain

8-7.0
General Information Regarding Flat Maple Dieboards
for Dieboard Routing Systems
Flat Maple Dieboards
Wood Species --
species which have physical characteristics comparable to Hard Maple.
Surface Finish --
Face --Sanded smooth - no voids.
Back -- Sanded smooth - no voids.
NOT ACCEPTABLE
Face -- Rotary cut, smooth, tight cut, full length
Holes, voids, splits
Open joints or cracks
Foreign particles
Heavy bird’s-eye
Burls over 1"/25mm or cracked
Interior cracks or splits exceeding 1/8"/3.2 wide x 2"/51 long
Glue -- No specific requirements

8-7.1
for
Maple Dieboards
Maple Dieboards - Flat

Tolerance Tolerance
N/A Number of Plies 5 or 7 5 or 7 Cold press or
high frequency
laminated
N/A Moisture < 8% Oven Dry < 8% Oven Dry per ANSI/HPVA
Weight Weight HP-1-1994*
N/A Specific Gravity 0.63 - 0.68 0.63 - 0.68
N/A Length or Width +/- .125" +/- 3.175 mm
N/A Thickness + .005" + .127 mm
- .015" - .381 mm
Under 60" Flatness +/- .125" +/- 3.175 mm **
1.5 m
Over 60" Flatness +/- .188" +/- 4.763 mm **
1.5 m
N/A Twist +/- .005" +/- .127 mm
Under 48" Squareness +/- .063" +/- 1.588 mm per ANSI/HPVA
1.23 m HP-1-1994*
Over 48" Squareness +/- .094" +/- 2.381 mm per ANSI/HPVA
1.23 m HP-1-1994*
N/A Straightness +/- .063" +/- 1.588 mm per ANSI/HPVA
HP-1-1994*
* As published by the American National Standards Institute
** Flatness is determined by placing board, “hump” up, on a flat,

recently scraped or Blanchard ground, knifing table.
If “hump” does not flatten out, measure the amount of warp.

8-8.0A
Maple Dieboards for Dieboard Routing Systems
Maple Dieboards - Flat

Tolerance Tolerance
N/A Number of Plies 3 or 5 3 or 5 Cold press or
high frequency
laminated
N/A Moisture < 8% Oven Dry < 8% Oven Dry per ANSI/HPVA
Weight Weight HP-1-1994*
- .010" - .254 mm
Under 60" Flatness +/- .25" +/- 6.35 mm **
1.5 m
Over 60" Flatness +/- .365" +/- 9.525 mm **
1.5 m
N/A Twist +/- .005" +/- .127 mm
Under 48" Squareness +/- .063" +/- 1.588 mm per ANSI/HPVA
1.23 m HP-1-1994*
Over 48" Squareness +/- .094" +/- 2.381 mm per ANSI/HPVA
1.23 m HP-1-1994*
N/A Straightness +/- .063" +/- 1.588 mm per ANSI/HPVA
HP-1-1994*
* As published by the American National Standards Institute
** Flatness is determined by placing board, “hump” up, on a flat,

recently scraped or Blanchard ground, knifing table.
If “hump” does not flatten out, measure the amount of warp.

8-8.1A
General Information Regarding Flat Birch Dieboards
Flat Birch Dieboards
Boards are available from Finland, Poland, Russia, and Latvia as well as other
Baltic nations.
Birch dieboard is constructed of 1/16"/1.59mm thick, rotary cut veneers.
The grade utilized in the diemaking industry is bb/bb. This grade allows tight
oval patches on both sides of the board.
Another grade, b/bb, allows patches on one side only leaving one side clear.
Grade b/bb does however demand a higher price.
A critical aspect to consider when ordering birch dieboard is whether it is

manufactured using the dark glue line (not laser compatible) or the clear white
glue line which can be cut with a laser.

8-9.0
for
Birch Dieboards
Birch Dieboards - Flat

Tolerance Tolerance
N/A Number of Plies 7, 9, 12 or 14 7, 9, 12 or 14
N/A Moisture 10% to 12% 10% to 12%
Oven Dry Oven Dry
Weight Weight
- .020" - .508 mm
Under 60" Flatness +/- .180" +/- 4.572 mm
1.5 m
Over 60" Flatness +/- .200" +/- 5.080 mm
1.5 m
N/A Twist +/- .020" +/- .508 mm
Under 48" Squareness +/- .100" +/- 2.540 mm
1.23 m
Over 48" Squareness +/- .125" +/- 3.175 mm
1.23 m
N/A Straightness +/- .100" +/- 2.540 mm

8-10.0A
General Information Regarding Flat Birch Dieboards
for Dieboard Routing Systems
Flat Birch Dieboards
Boards are available from Finland, Poland, Russia, and Latvia as well as other
Baltic nations.
Birch dieboard is constructed of 1/16"/1.59mm thick, rotary cut veneers.
The grade utilized in the diemaking industry is bb/bb. This grade allows tight
oval patches on both sides of the board.
Another grade, b/bb, allows patches on one side only leaving one side clear.
Grade b/bb does however demand a higher price.
Since there is no restriction on glue, either dark glue line or clear/white (laser
compatible) glue line may be used.

8-10.1
Birch Dieboards for Dieboard Routing Systems
Birch Dieboards - Flat

Tolerance Tolerance
N/A Number of Plies 5, 6 or 7 5, 6 or 7
N/A Moisture 10% to 12% 10% to 12%
Oven Dry Oven Dry
Weight Weight
- .012" - .300 mm
1.5 m
Over 60" Flatness +/- .375" +/- 9.525 mm
1.5 m
N/A Twist +/- .020" +/- .508 mm
1.23 m
1.23 m

8-10.1A
General Information Regarding Flat Beech Dieboards
Flat Beech Dieboards
Beech dieboard is currently imported from both Germany and Poland.
German Beech is very similar in construction to domestic maple and is available

in panel sizes up to 60"/1.54m x 144"/3.66m. It can be laser cut.
Polish Beech is similar in construction to Finland Birch plywood. It can be laser

cut. The product is currently not widely available in the United States.

8-11.0
for
Beech Dieboards
Beech Dieboards - Flat

Tolerance Tolerance
5/8" Number of Plies 7 or 12 7 or 12
3/4" Number of Plies 7 or 14 7 or 14
N/A Moisture 10% 10%
Oven Dry Oven Dry
Weight Weight
- .020" - .508 mm
1.5 m
Over 60" Flatness +/- .200" +/- 5.080 mm
1.5 m
N/A Twist +/- .020" +/- .508 mm
1.23 m
1.23 m

8-12.0A
for
Permaplex Platinum Dieboards
Dieboard material consisting of cellulosic fibers and polyester resin.
Permaplex Platinum Dieboards - Flat

Tolerance Tolerance
3/8" Number of Plies 7 - 9 plies 7 - 9 plies
1/2" Number of Plies 10 - 12 plies 10 - 12 plies
5/8" Number of Plies 13 - 15 plies 13-15 plies
11/16 Number of Plies 15 - 17 plies 15 - 17 plies
N/A Moisture 1.0% Oven Dry 1.0% Oven Dry
Weight Weight
N/A Specific Gravity 1.34 gr/cc 1.34 gr/cc
48"x80" Length +/- 2.00" +/- 51 mm
48"x60"
48"x80" Width +/- .500" 13 mm
48"x60"
3/8", 1/2", 5/8" Thickness +/- .005" +/- .13 mm
1.5 m
Over 60" Flatness +/- .188" +/- 4.78 mm
1.5 m
N/A Twist +/- .020" +/- .508 mm
48"x80" Squareness within .125" within 3 mm
Diagonal
Measurement
48"x80" Straightness within .062 within 1.5 mm

(Parallelism)
N/A Flexural Strength 22,000 psi 151.68 MPa
(MOR)

8-13.0A
General Information Regarding Rotary Maple Dieboards
Rotary Maple Dieboards
Wood Species --
pieces which have physical characteristics comparable to Hard Maple.
Surface Finish --
Face --Smooth no voids.
Back -- Smooth no voids.
Sanded finish not required either side.
NOT ACCEPTABLE
Holes
Open cracks.
Small cracks not to exceed 1/8"/3.2mm wide x 2"/51mm long may be
filled with wood filler and sanded smooth.
Heavy bird’s-eye
Burls over 1"/25mm or cracked
Interior cracks or splits exceeding 1/8"/3.2mm wide x 2"/51mm long

8-14.0
for
Maple Dieboards
Maple Dieboards - Rotary

Tolerance Tolerance
N/A Number of Plies 5, 7, 8 or 10 5, 7, 8 or 10
N/A Moisture < 7% Oven Dry < 7% Oven Dry
Weight Weight
N/A Width +/- .125" +/- 3.175 mm
(Left to Right)
N/A Length +.162" -.125" +4.115 mm
(Press Direction) over 30" -.175 mm over 76 cm
½" Thickness + .031" + .787 mm
12.70 mm - .000" - .000 mm
5/8" Thickness + .000" + .000 mm
15.875 mm - .031" - .787 mm
ID < 15" Inside + .063" + 1.588 mm
380 mm Diameter - .125" - 3.175 mm
ID 15" to 22" Inside +/- .125" +/- 3.175 mm
380 mm to 559 mm Diameter
ID > 22" Inside + .125" + 3.175 mm
559 mm Diameter - .250" - 6.350 mm
ID <13.5" Convex Distortion + .063" +1.588 mm
343 mm
ID >13.5" Convex Distortion + .094" + 2.381 mm
343 mm
N/A Concave +/- .000" +/- .000 mm
Distortion
1.83 m
1.83 m
N/A Twist + .250" + 6.35 mm

8-15.0A
CHAPTER 9
AUTOMATIC RULE BENDING
General Information Regarding Automatic Rule Bending Machines
Purchasing Considerations
When contemplating the purchase of automated bending equipment, the diemaker should take
the following factors into consideration:
Productivity -- A definable and achievable increase in productivity should be of primary

consideration when considering an automatic rule bending machine.
On-Time Delivery -- The use of the automatic rule bending equipment should enable the
diemaker to improve their turn around time in the production of dies.
Return on Investment -- The use of the automatic bending equipment should provide a return
on investment that will satisfy the criteria set forth in the diemakers financial objectives.
Ease of Use/Training -- The automatic rule bending equipment should be easy for the diemaker
to learn and to operate. “User friendly” is a term which is very justified in this situation since
most diemakers will not initially be comfortable or proficient with computerization.
Ensure Precision and Consistency -- An automated rule bending system should ensure
precision within the tolerances defined by the manufacturer of the equipment and should
maintain consistency especially when producing multiple identical pieces.
Multiple Uses -- The equipment should be versatile and usable on a wide variety of bending
requirements to satisfy the diemakers needs.

Automating The Processing Of Steel Rule
Note: This article has been reprinted from the March 1995 issue of IADD’s The Cutting Edge.
The advent of numerous pieces of equipment way. While none of the manufacturers yet claim
which is designed to process rule for insertion into perfection in all phases of rule processing, the
the dieboard has taken center stage for the diemaker amount of progress made in the past 2 years would
and diecutter. indicate that the technology is viable and
The reason this equipment is on the mind of economically feasible for a vast majority of the
every person involved in the converting industry is converting industry.
the fact that few, if any, believed that this operation As we embrace this technology and it
could ever be automated. There were many good becomes an operating part of our production system,
reasons for this attitude, not the least being that the we must exercise what I will call conceptional error.
actual steel used in the rule varied enough to prevent By this I mean let’s not jump to erroneous
machines from tweaking the rule to the exact kerf conclusions. Such as, we no longer need traditional
requirement. bench skills, the cost of dies will drop dramatically,
There were many other reasons which seemed or that lead time for complex dies will be measured
to preclude the automation of rule processing. in hours not days.
However, most of our industry took the We must remember that these machines affect
position if such a system could be developed, the only rule processing. While rule processing is the
industry would embrace the technology with open most visual operation in diemaking, it is not the most
arms. time consuming or expensive path of the overall
We have seen in the past few years the production cycle.
development of automated systems to accomplish at Most rule processors will be installed not for
least 90% of rule processing automatically. The cost or speed, but because we cannot as an industry
development of these systems has occurred all across keep up with the demand for dies in the traditional
the world; United States, England, Japan, Korea, manner. We simply can not hire and train people to
Germany, and Italy, and perhaps today will see yet meet the peak production demanded and the reduced
another player in the arena of automation. turn around demands. The ability to do more without
Each of the systems has taken a different expanding our labor force, will drive this equipment
approach to resolving the problems of rule into our industry. Not speed and cost.
processing. All of these approaches have proven that
it is possible to solve a problem in more than one

Automatic Rule Bending Systems
Unmasking the Myth of 100% Automation
Note: This article has been reprinted from the March 1995 issue of IADD’s The Cutting Edge.
Written by Robert Larson, President, Larson WorldWide, Norwell, MA, USA.
Two of the hottest new technologies to hit the systems are not worthy of the expense and all the hoopla
steel rule diemaking industry are the automatic process- that has been promoted on automatic bending of steel
ing of steel rule blades and the automatic bending of rule blades.
steel rule blades. These two new concepts have been Let me clear the air on this subject. Automatic
widely publicized and could become the dream come bending of steel rule blades was never intended to
true for many steel rule diemakers who are looking for entirely replace the skilled diemaker who produces steel
ways to automate their decades old hand skilled, crafts- rule dies.
man based methods of producing steel rule dies for the With all the systems that are currently in the
converting industry. marketplace today, no one system claims to be able to
Many diemakers dreamed of the day when they automatically bend all shapes and configurations of a die
could further automate their operations beyond the laser blade. That was never the ultimate intention of the
for automatically producing dieboards. In the past ten or wizards who conjured up the idea of automatic rule
so years, several companies have developed semi- bending. Remember Colin Pitcher’s comment in that the
automatic systems for processing steel rule, but it is systems are “an aid to the diemaker, not a means of
only in the past few years did the reality of rule bending replacing him.” Their prime motivation was to create a
truly become available into the marketplace. Of course, system that would automatically bend let’s say 50% of
it was the advent of the computer and CAD/CAM the configurations in any die and be able to accurately
programs that provided the engine that allowed forward reproduce as many duplicate blades as may be required
thinking individuals in the diemaking industry to create in a die design.
these new processes. We must look at the practicality of utilizing an
In discussing this subject with Colin Pitcher, automatic rule bender in the diemaking process. If you
[formerly] Managing Director of Notting, he mentioned are producing a single cavity die design with few if any
one basic truth that we must all consider. Today, steel duplications of the same designs, it may be faster to
rule diemakers are working in a marketplace where hand bend the sections. Let me make one comparison
there is no longer a recognized apprenticeship scheme, that may shed some light on the new process of
hence there are fewer trained diemakers coming into the automatic bending.
industry. However, the same number or greater number Go into practically any steel rule die company
of fully trained diemakers are retiring, therefore the that has installed a laser to burn dieboards. Seldom will
total number of fully skilled experienced diemakers are you find jig saws being used to cut dieboards in these
diminishing. This means that good diemakers are shops. In their adjusting to the new technology of
becoming a “Premium Product.” Mr. Pitcher pointed utilizing the laser to burn dieboards, they soon
out that the automatic rule bending machine is an “aid discovered that it was better to burn all dieboards. Yes,
to a diemaker” and “not a means of replacing him.” some of the simpler layouts could still be cut by hand on
Many diemakers took the word “automatic” in a jig saw, but, most laser shops soon recognized that it
rule bending too literally. They seemed to envision the was more efficient and more accurate to burn all their
totally automatic machine that would spit out their rule dieboards. Using this same thought process, in shops
100% bent to whatever shape they wanted and ready to that I have been in that are currently utilizing rule
drop into a dieboard. After looking at the different processing equipment and rule bending equipment, after
systems that are currently in the marketplace, a they successfully integrated the systems into their
grumbling appeared to surface amongst many diemakers production process they soon appreciated the fact that all
that these automatic systems are not 100% automatic rule should be processed and as much of the rule, as
and are not the ultimate solution. Therefore, these possible, should be automatically bent. You will note I
said “as much of the rule, as possible, was bend the letter often in 10% of the time it would take a
automatically bent” since we all know that today it is skilled diemaker to accomplish the same functions.
impractical to expect that all rule can be 100% Mr. George Kakridas, President of CNC
automatically bent. Corporation, also wanted to make the point in the case
We can look at a typical folding carton design. of bending a Christmas tree design, for example, most
For example, take a typical 10 up die design and you diemakers want to bend that shape in one or as few
will discover that approximately 75% of the rule is pieces as possible. The automatic rule bender can
straight requiring no angles or bends. The other 25% of efficiently, in many cases, bend long sections of rule. A
the blades may require one or more single bends that in limiting factor comes into play where there may be one
many cases could be hand bent on a bender that was set or more sharp angles or bends in the design. The CNC
up to do the task. Mr. Pitcher commented on my system is limited to bending an angle of 110o with a .
estimate of the percentages of how effective an 030" inside radius. If the angle of any bend has to be
automatic bender could be in production. He said less than 110o , then a diemaker must close up the angle
“When we talk of percentages, it could be said that in on a hand bender. This is not a big drawback because
folding carton dies approximately 60% are straight rule, the automatic bender has already saved a considerable
all of which can be produced on a rule processor. amount of a diemakers time where he can be productive
If the same processor can only produce 50% of in doing other work on other dies.
the bent rules, it still produces overall 80% of the rules Talking to Jay Newman, who had installed two
needed in the die. This still leaves the more skilled automatic rule benders at Mead Packaging in Atlanta,
craftsman, taking away the boring, mundane work Georgia, before he retired to become a consultant, he
which does not require his or her talents. ”Here again, stated that his diemaker rapidly saw the advantages of
percentages are an opinion of different sources in the let’s say 50% to 70% bending capabilities of the
diemaking community, but it is fair to say that my automatic bender. It was extremely easy and fast to
percentages and Mr. Pitcher’s percentages indicate a close up a partially bent angle. They appreciated how
somewhat parallel course of agreement. the new automatic benders made their jobs easier and
Where an automatic bending system comes truly made them more productive.
into positive advantage, it is in bending blades with It is only logical that some diemakers who do
many angles. For example, let us say that we had to not understand the true capabilities of automatic rule
make a die in the design of a Christmas tree, an outline bending will take the negative opinion that the present
of a train or an outline of some shape with many bends automatic rule benders on the market are not good
and shapes. This is where an automatic bending system enough for the money that is being charged for them.
truly comes into it’s glory. Let us take a look at the diemaking process, and
In early studies that I did with CNC Corporation I think it will be easy to see these new automatic rule
of Lowell, Massachusetts, in the development of their processing and rule bending systems, are well worth
first automatic bending system, they did comparison their investments once a diemaker learns how to use
time studies of comparing hand bending time with the these new systems. In learning any new system,
time it took their automatic bender to produce the same everyone has to recondition themselves to a new way of
rule configuration. The results showed that as the doing things and then adjust their thinking on the way
bending process required more angles and their manufacturing process works. There will be a
configurations, the automatic bender could cut the time learning curve where a diemaker has to retrain his
down to 25% to 10% of the time it would take a skilled employees and adjust old habits. Old diemakers proud
diemaker to do the same operations. These savings in of their hand skills and diemaking expertise will most
times, of course, depend on many factors. One example likely resist these new systems as a threat to their
was with a customer who produced alphabet dies. This craftsmanship. On the other hand, younger diemakers
customer claimed that depending upon the complexity of will probably adapt more swiftly to new methods of die
a particular letter in the alphabet, he could automatically manufacturing. I strongly believe that once diemakers
realize how these systems can save time (and time costs Adams [formerly] of Ken Specialties, “since the rule
money) and improve their capabilities to produce sections can begin or end on a radius.” The BBS-Pro
accurate, quality dies, that they will fully understand the system is available to accommodate either coil or strip
merits of using automatic rule processing and rule fed rules.
bending equipment. As skilled diemakers do become a I am going to try to justify the reasoning behind
scarcer entity, their valued time must be efficiently why one vendor approaches the rule processing and rule
utilized and the simple more mundane elements of their bending of rule in different ways. Each company can
jobs must be reevaluated. The rule processor and explain their rationale as to why their system works in
automatic bender will make a diemaker more productive the way they have designed it. I will say that I
and efficient. personally feel a two stage system where you process
I have closely watched the development of rule the rule and then bend the rule does make sense from a
processing and rule bending for the past five or so diemakers point of view, being an old diemaker myself.
years. I see two totally different new processes in the As explained earlier, not all rule that is processed needs
diemaking process, one being the processing of the rule to be bent. There are definite advantages of pre-
and the other being the bending of the rule. It is my processing all rule going into all dies in a die shop. A
opinion that we must look at these two processes dedicated rule processor is more efficient in supplying
separately. pre-processed rule to diemaking stations. Those sections
When we look at the current automatic systems of rule that should be 100% or partially bent due to
that are available today we see needs. For example, angle restrictions can then be processed in the automatic
both the Sandvik CNC system and the Notting system bender unit.
take the approach to combine automatic rule processing The key to efficient productivity of steel rule die
and rule bending into one system. Both of these systems manufacturing today as in the future, will be providing
provide the bent rule cut exactly to size, with either a the skilled diemaker with all the components required to
straight or mitered cut, and with all bridge notches cut produce a die. Each diemaker then can concentrate his
in their exact location. Even if straight sections of rule or her time (again. . . time is money) in assembling the
are required for a die, those sections are processed pre- processed sections of the die into the final die. Now
through the system. here is where the savings come into play. I have
The Laserck system separates the processes by discussed this with many diemakers, especially in Japan
providing two units. Their Master Cutter, which and Europe, who are using advanced automatic rule
processes the rule to exact length with either straight or processing and bending techniques. It is possible to save
mitered cuts, along with bridge notches. The precut rule up to 80% of the diemakers time when he or she is
sections are then loaded into their Master Bender Unit supplied with all the components to produce a die. It is
where they are bent to the desired shapes. The Laserck also possible to structure a shop so that support
system allows one Master Cutter to support up to three personnel prepare the rule and dieboard, so that the
Master Benders depending upon production diemaker provides the truly critical task of placing the
requirements. Laserck also claims that by processing rule into the die with any necessary adjustments. He
lengths of rule vs. rule from a coil, they can more would close up any angles that were too tight for the
accurately control the close tolerance and accuracy of automatic bender and do that final tweaking, to make a
rule sections generated by their systems. perfectly fit die to its original specifications. Let’s face
The Tsukatani BBS-Pro system sold by Ken it, a diemakers skill shines in the final adjustment of the
Specialties takes a third approach. The bending station blades, and with automatically bent rule, the situation is
bends the rule to fit a CAD file, and automatically adds the same.
a set length to the end of the rule section. The ends are
then processed on a separate station. The rule sections
are then notched conventionally. “This approach allows At the end of a production day, a diemaker will
the system to bend more complex shapes”, says Mike be far more productive and could produce more dies in
a typical eight hour shift. length in a die to produce an outline of a 12 inch high
The bottom line is that using new technology Christmas tree, it could take a diemaker several hours to
like automatic rule processing and automatic rule get the rule ready to put into the dieboard. An automatic
bending, diemakers will become more efficient and rule processor and bender can do the same functions
productive. within minutes, therefore saving much time out of
A diemaking company will be able to produce manually doing the same operations. I have not tried to
more quality dies without adding more diemaking be simplistic, just realistic. The more complex the task,
personnel. The key to success in this new method of the greater benefits and time savings are derived from
production, is understanding the capabilities of the process.
automatic rule processing, and the advantages and In conclusion, if you have it in your mind that
limitations of automatic rule bending. Then you’re seeking a totally automated bending system, then
implementing those capabilities into your diemaking forget it at least for the immediate future. The systems
operations. that are available today, definitely have a place in the
As in any new emerging technology, a lot of steel rule die manufacturing process. They are a definite
misinformation, myths and false rumors persist in the aid in improving productivity in the die shop. As I have
marketplace. said, you must understand the benefits of automatic rule
No, an automatic rule bender is not going to processing and automatic rule bending, and then learn
completely automate your bending functions. It will how to adapt the new procedures into your particular
greatly enhance your operations. operations. Those diemakers who are open to new ideas
Automatic rule benders truly shine in situations and new ways of producing cutting dies will be winners,
where you have many shapes and angles in a die. For others will just muddle along and never see the light.
example, to prepare the rule, notch it, bend it, cut it to

General Information Regarding Automatic Bending Equipment/Systems
Features/ CNC Tsukatani Laserck Ideon Prime
Capacities: Technology
Hardware 1 year 6 months parts 1 year 1 year 1 year

Warranty 90 days labor
Software 1 year 1 year 1 year 1 year 1 year

Warranty
Coils Yes Yes Future Yes Yes
Strips Optional Yes Yes Yes Yes
Rule 1 ½ - 2 ½ pt. 1 ½ - 3 pt. 1 ½ - 3 pt. 1 ½ - 6 pt. 2 pt.

Thickness
Notches Yes Off Line Yes Yes Yes
Miters Yes Off Line Yes Yes Yes
Bend, Tight 115o 95o 90o 95o N/A
Bend, Large 360o 360o 360o 360o N/A
Starts Bend Yes Yes Yes Yes N/A
Marks Bend N/A N/A N/A N/A Yes
Computer IBM Compatible IBM Compatible IBM Compatible IBM Compatible IBM Compatible
Type
Software/File DDES, DXF; DOS, Win 95, Custom DDES-2, DXF, DOS
Types CFF2; Windows NT/3.x, IGESS; DXF G-Code Data,
Windows 3.1 DDESII, DXF, Windows 3.1/95
G-Code
Height Set Up 30 sec. 30 sec. 30 sec. 30 sec. 1 hr.
Miter Set Up 30 sec. 10 min. 5 min. 30 sec. 1 hr.
Nick Set Up N/A N/A N/A N/A N/A
DeCurl Set 3 min. 10 min. 10 min. Automatic 10 min.

Up with coil
Lower Rule .500" .472" .898" .472" .918"

Height 12.7mm 12mm 22.9mm 12mm 23.3mm
Higher Rule 1.000 - 1.125" 1.250" 1.000" 2.000" 1.000"

Height 25-28mm 32mm 25mm 51mm 25mm
Disks Yes Yes Yes Yes Yes
Separate Yes Yes Yes Yes Yes

Power Line

R0
(Continued)
Features/ CNC Tsukatani Laserck Ideon Prime

Capacities: Technology
Notcher Type Custom Custom Custom Automatic Custom
Notcher Hits 10 - 20 M Unknown 40 M Unknown Unknown
Resharpen Yes Yes Yes Yes Yes

Notcher
Notcher Set 15 - 30 min. Nominal 1 hr. 30 seconds Nominal

Up
Miter Type Custom Custom Custom Automatic Custom
Miter Hits 10 - 20 M Unknown 20 M Unknown Unknown
Miter Angle Customer Customer Customer Customer Customer

(Degrees) Specified Specified Specified Specified Specified
Miter Set Up 15 - 30 min. Nominal 1 hr. 30 seconds Nominal
Type Cut Off Cut Bend Cut Bend or cut Cut
Cut Off Angle Customer Customer 90o 90o N/A

(Degree) Specified Specified
System CNC Tsukatani Laserck Ideon Prime

Components: Technology
Computer 1 1 2 1 1
Notcher 1 1 1
Miter 1 1
Bender 1 1 1 1 1
Coil Feed 1 N/A By Customer
Strip Feed 1
TOTAL 3 w/vision 5 4 4 2
monitor

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(Continued)
Accuracy: CNC Tsukatani Laserck Ideon Prime

Technology
Cut Length +/- .003" +/- .003" +/- .001" +/- .0025" +/- .002"
Accuracy +/- .076mm +/- .076mm +/- .025mm +/- .064mm +/- .051mm
Bend +/- .2o +/- .2o +/- .005o +/- .2o N/A
Accuracy
Repeatability +/- .003" Rule +/- .001"/.025mm Rule +/- .002"

+/- .2o Consistency +/- .005o Consistency +/- .051mm
Notch +/- .003"/.076mm Off Line +/- .010" +/- .001" +/- .002"
Accuracy +/- .076mm by Operator +/- .254mm +/- .025mm +/- .051mm
Miters +/- .003" Off Line +/- .010" +/- .001" +/- .002"
Accuracy +/- .076mm +/- .001"/.025mm +/- .254mm +/- .025mm +/- .051mm
Software CNC Tsukatani Laserck Ideon Prime

Features: Technology
Add Length Yes Yes Yes Yes Yes
Subtract Yes Yes Yes Yes

Length
Qualify Bends Yes Yes Yes Yes N/A
Enlarge Area Yes Yes Yes Yes Yes
Functional CNC Tsukatani Laserck Ideon Prime

Set-ups Technology
Length CAD File CAD File N/A CAD File CAD File
Notch CAD File Off Line N/A CAD File CAD File
Location
Miter Cut Operator Operator N/A Operator Operator
Straight Cut Operator Operator N/A Operator Operator
Bend Operator CAD File N/A Operator N/A

Direction

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(Continued)
Installation CNC Tsukatani Laserck Ideon Prime

Requirements: Technology
Volts 115 AC 110 AC Cutter 220 110 AC 220 AC

AC
Bender 110
AC
Amps 15 Amp 14 Amp Cutter 10 10 Amp

Amp
Bender 30
Amp
Phase Single Single Single Single Single
Air Pressure 90 PSI N/A 90 PSI N/A 80 PSI
Other CNC Tsukatani Laserck Ideon Prime

Capabilities: Technology
Rule Caliber With Vision

Monitor
Software Log:
Cumulative Yes
Tool Hits
Cumulative Yes
Rule Length
(Note: As new equipment comes on the market we will attempt to chart the same features.)
IADD Product Information 9-109-10

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(Continued)
Features/ Easy Bender Easy Cutter Suntex Notting

Capacities: America
Hardware 1 year 1 year 1 year 1 year

Warranty
Software 1 year 1 year 1 year 1 year

Warranty
Coils Yes Yes Available Yes
Strips Yes Yes Yes
Rule 1 ½ - 2 pt. 1 ½ -3 pt. 1 - 6 pt. 2-3 pt.

Thickness
Notches Yes Yes Off Line Yes
Miters Yes Yes Off Line Yes
Bend, Tight 135o N/A 90o 140o
Bend, Large 360o N/A 360o 270o
Starts Bend Yes N/A Yes Yes
Marks Bend Yes Yes N/A N/A
Computer IBM IBM Custom IBM

Type Compatible Compatible Compatible
Software/File DDES2, DDES2, DDES, DXF, Custom

Types DXF; G-Code DXF, G-Code CF2, DOS Notting
Height Set Up 5 min. 5 sec. Custom. 30 min.
Miter Set Up 5 sec. 5 sec. N/A. 5 min.
Nick Set Up 5 sec. 5 sec. N/A N/A
DeCurl Set 5 min. 5 min. N/A N/A

Up
Lower Rule .500" .500" .472" .500"

Height 12.7mm 12.7mm 12mm 12.7mm
Higher Rule 1.000" 1.000" 2.000" 1.000"

Height 25mm 25mm 51mm 25mm
Disks Yes Yes Yes Yes
Separate Yes Yes Yes Yes

Power Line

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(Continued)
Features/ Easy Bender Easy Cutter Suntex Notting

Capacities: America
Notcher Type Custom Custom N/A Custom
Notcher Hits Unknown Unknown N/A 20 M
Resharpen Yes Yes N/A Yes

Notcher
Notcher Set 5 sec. 5 sec. N/A 5 min.

Up
Miter Type Custom Custom N/A Custom
Miter Hits Unknown Unknown 20 M 20M
Miter Angle Customer Customer Customer Customer

(Degrees) Specified Specified Specified Specified
Miter Set Up 5 sec. 5 sec. N/A 5 min.
Type Cut Off Bend or Cut Cut Bend Cut
Cut Off Angle Customer Customer Customer 90o

(Degree) Specified Specified Specified
System Easy Bender Easy Cutter Suntex Notting

Components: America
Computer Built In Built In 1 1
Notcher Built In Built In --
Miter Built In Built In --
Bender Built In N/A 1 1
Coil Feed Built In Built In -Up 1

to 6
Strip Feed 1
TOTAL 1 1 4 2

R0
(Continued)
Accuracy: Easy Bender Easy Cutter Suntex Notting

America
Cut Length +/- .002" +/- .002" +/- .0025" +/- .001"
Accuracy +/- .051mm +/- .051mm +/- .025mm
Bend +/- .2o +/- .2o +/- .2o +/- .001""

Accuracy +/- .025mm
Repeatability +/- .002" +/- .002" Rule +/- .001"/.025mm

+/- .051mm +/- .051mm Consistency or 1o
Notch +/- .002" +/- .002" N/A +/- .001"

Accuracy +/- .051mm +/- .051mm +/- .025mm
Miters +/- .002" +/- .002" N/A +/- .001"

Accuracy +/- .051mm +/- .051mm +/- .025mm
Software Easy Bender Easy Cutter Suntex Notting

Features: America
Add Length Yes Yes Yes Yes
Subtract Yes Yes Yes Yes

Length
Qualify Bends Yes Yes Yes Yes
Enlarge Area Yes Yes Yes Yes
Functional Easy Bender Easy Cutter Suntex Notting

Set-ups: America
Length CAD File CAD File CAD File Yes
Notch CAD File CAD File Off Line CAD File

Location
Miter Cut Operator Operator Operator Operator
Straight Cut Operator Operator Operator Operator
Bend Operator Operator Operator Operator

Direction

R0
(Continued)
Installation Easy Bender Easy Cutter Suntex Notting

Requirements: America
Volts 110 AC 110 AC 115 AC 110 AC
Amps 10 Amp 10 Amp 10 Amp 15 Amp
Phase Single Single Single Single
Air Pressure 80 PSI 80 PSI N/A N/A
Other Easy Bender Easy Cutter Suntex Notting

Capabilities: America
Rule Caliber Future N/A
Software Log: Future Future
Cumulative Future Future

Tool Hits
Cumulative Future N/A

Rule Length
(Note: As new equipment comes on the market we will attempt to chart the same features.)

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General Information Regarding Automatic Bending
Automation Of The Diemaking Process
Written by Mike Adams, [formerly of] Ken Specialties, Inc., Wood Dale, IL, USA.
The diemaking industry has made LASER SYSTEMS & CAD

considerable progress toward the goal of automating ° Quality and Consistency are improved
tasks that are repetitive, physically taxing, and ° Turn around time is reduced
potentially harmful. ° Productivity is increased
The IADD has been a major catalyst for this One of the first automated functions, CAD
progress. Through the years the association has systems and Lasers have improved quality and
provided a forum for members to be exposed to consistency.
new technologies as they are introduced. We have Turn around time has been reduced,
seen advances in the area of CAD and lasers, as allowing diemakers to be more responsive to
well as advances in methods of controlling and customers.
measuring the process. I would like to commend the Contrary to what some might think, the
officers and members of the association for sharing advent of Laser systems and CAD have not resulted
information among themselves. This is the way a in loss of jobs within the industry. It has resulted in
discipline advances; sharing information. We the shifting of people from one task to another, and,
realize that technology is not a replacement for in many cases, the hiring of additional personnel to
people, rather, it provides tools for people. We keep up with the increased productivity.
know that quality is extremely important, and
people need tools to help them improve quality OFFICE AUTOMATION
while increasing productivity. As an industry we ° Information and Control
must continue this commitment to improve the ° New systems make it easier than ever
diemaking process. ° It’s worth the price
I am including in this category all the
ADVANCES IN AUTOMATION functions involving information and control. These
All of the following functions can be automated, at tasks were almost impossible to manage before the
least to some degree, with the technology available introduction of computers and software to handle
to us today. them. It simply took too long to manually collect
° Dieboard Cutting the information (for example) for a Statistical
° Design Process Control system.
° Office Information Today, there are relatively low-cost systems
° Shipping & Receiving that handle estimating, order entry, accounting,
° Job Tracking & Data collection inventory control, data collection, job tracking, and
° Rule Bending even shipping and receiving. I believe it is wise to
° Rule Processing address these areas before making a major purchase
I have divided the functions into three such as a laser. Unfortunately, justifying the
categories: investment in office automation is difficult. It is
Dieboard Cutting and Design hard to estimate a return on your investment when
(programming) the benefit of these systems do not easily translate
Information Management into dollars. But in my opinion, it’s worth the price!
Rule Bending and Processing

R0

AUTOMATED RULE BENDERS AND RULE automated bender. The times recorded included
PROCESSORS everything from opening the CAD file, to completely
° Changing trends ruling the die.
° Meets a critical need In this first example, three shapes in a
° Provides a solution to an existing combination layout measured about 17" x 22". It was
personnel problem produced as a single combination and as a 3 up die.
In the past, for a small to mid size die shop, The 3 up die had 3 each of the 3 designs, for a total
the conventional wisdom seemed to be that they of 9 cavities in the die. The one up combination took
would first purchase CAD, then a laser, and finally a total of 210 minutes manually, and 72 minutes with
they would address the needs of the office. With the the automated bender. The 3 up die took 300 minutes
introduction of automated rule benders and rule manually and 120 minutes with the automated
processors, I see this trend changing. bender.
Many of the companies that have purchased In the second example, four shapes in a
these systems or who plan to purchase them tell me combination layout measured about 7" x 9". It was
that they can buy laser burned boards from outside produced as a single combination and as a 20 up die.
suppliers at reasonable prices, and with excellent turn The 20 up die had 20 each of the 4 shapes, for a total
around. For them, this equipment addresses a more of 80 pieces in the die. The one up combination took
critical need, the bottleneck caused by manual a total of 120 minutes manually, and 12 minutes with
bending. the automated bender. The 20 up die took 550
Most of these companies have told me that minutes manually and 72 minutes with the automated
they are shorthanded, and are having difficulty bender.
finding trained personnel. This equipment offers the In the third example, the shape in the layout
opportunity to increase quality and productivity measured about 5" x 7". It was produced as a single
without having to invest years in training additional die and as a 5 up die. The one up die took a total of
people. 90 minutes manually, and 16 minutes with the
automated bender. The 5 up die took 180 minutes
TIME STUDY manually and 48 minutes with the automated bender.
Katoh Steel Rule Die is one of the top 5 diemakers in
Japan. They have 2 lasers and 3 BBS automated rule
benders. I visited the plant when I traveled to Osaka ONE UP DIE SETS
a few months ago, and I was surprised by the fact that Here are the time savings obtained using the
the die shops seem to be behind us in many ways, automated bender on the one up sets.
such as Laser equipment and CAD. In the area of rule Example 1: 210 minutes manually;
benders and processors, however, they have invested 72 minutes with the automated bender.
heavily in technology. There are over 100 BBS Example 2: 120 minutes manually,
automated steel rule bending systems operating in 12 minutes with the automated bender.
Japan. Katoh recently conducted a time study of jobs Example 3: 90 minutes manually;
produced both manually and with the BBS-Pro 16 minutes with the automated bender.

R0

MULTIPLE DIE SETS “The more expensive one!” He went on to

Here are the time savings obtained using the explain. “The equipment is paid for in the first year.
automated bender on the multiple die sets. The second year begins savings for the company.
Example 1: 300 minutes manually; Assuming the equipment has an effective life of 10
120 minutes with the automated bender. years or more, this can result in a dramatic difference
Example 2: 550 minutes manually; in overall savings!”
72 minutes with the automated bender.
Example 3: 180 minutes manually; OVERALL SAVINGS
48 minutes with the automated bender. In the hypothetical example, over the effective life of
The automated bender machines used in the the equipment, Equipment A will save the company
study were the older version of the automated bender. an impressive $900,000.00. On the other hand,
The current version is about 50% faster. Equipment B (which costs twice as much as
Increases in productivity ranged from about 3 to 1 on equipment A) saves the company 1.8 million dollars!
the low side to about 10 to 1 on the high side. The
productivity increases do vary based on how a shop NOT “IF” BUT “WHEN”
does things manually, and the mix of work they The bottom line for automated rule benders and
produce. processors is this:
These systems:
COST JUSTIFICATION # Free people from repetitive and
People decide to automate for many different potentially harmful tasks.
reasons. One owner of a three man die shop told me # Improve quality and consistency.
that he had decided to buy an automated bender-Pro # Help remove the bottleneck of manual bending.
system because it would allow him to spend more # Increase productivity
time with his family. Another owner told me that he # Increase profitability.
was concerned about Carpal Tunnel Syndrome and # Aid in the problem of finding and training
other injuries to his people. These are valid concerns personnel.
and should be considered, however, most people will For most companies involved in steel rule diemaking,
decide to automate because they can justify the the question is not “should we automate steel rule
equipment or system through cost savings. One bending and processing?” The question is: “when
manager of a large diemaking facility told me just should we automate?”
last week that he could pay for our automated rule
bender in a little over a year. He mentioned that he THE FINAL BRIDGE
could justify a similar piece of equipment in the same Steel rule bending and processing has been the last
amount of time, but the other equipment cost and most difficult part of our job to automate. During
considerably less. Then he told me he had decided to the first three quarters of 1994 many companies I
buy the more expensive equipment. He asked the spoke with were taking a “wait and see” attitude.
following question to illustrate his point. Most of the people I speak with now are telling me
“Two possible purchases, one costs that they will add this type of equipment during 1995.
$100,000.00 and the other costs $200,000.00. I can “When should we automate?”
justify either purchase in one year. Which one should The answer is NOW!
I buy?”

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Automated Rule Bending Systems
Note: This article reprinted from IADD’s The Cutting Edge, June 2001
Written by Robert L. Carter, Adams Technologies, Inc., Littleton, CO, USA.
One of the most popular programs at the IADD’s handled one or more times, they do not fit into the
recent Diecutting Odyssey showcased the newest category of automatic rule benders but could be more
technology in the flat, steel rule diemaking properly classified as semi-automatic bending and
process—fully automated rule bending systems. processing systems. Examples of what I have called
automatic rule benders, machines which do it all in a
This is one of the most exciting new technologies single station, would be the machines sold by Ken
in our industry, a technology which provides Specialties, Helmold and Adams Technologies.
significant benefits to both diemakers and diecutters.
The first rule processors—machines which could
This article will discuss the specific benefits cut, miter, and notch the rule—were introduced into
resulting from the implementation of this technology. the market in the mid-1980s. The earliest machines
Let’s take a few moments and review a little bit required manual programming.
of the history of the development of this technology. During the late 1980s, a computer interface was
It’s important for us to establish a clear definition of added which enabled the individual part parameters
exactly what the technology is. such as length of piece, number and position of
There are really three distinct types of systems in notches, etc., to be downloaded from the CAD files.
the broad classification of automated rule processing These are similar to the systems that are currently
equipment. Although many may lump these into a being marketed and are the machines that I am
single category, I think it is important to differentiate calling automatic rule processors.
between them—both to eliminate confusion and to The first rule benders were introduced in the early
establish common terminology throughout the 1990s. The earliest machines were pretty much
industry. limited to bending. The final cutting as well as the
Therefore, in this article, I will refer to machines notching and mitering was done on separate, stand
which do not bend the steel rule but which cut, miter, alone machines. These were the first of the semi-
notch and, in some cases, mark bending positions on automatic bending systems.
the rule as “automatic rule processors.” The current generation of automatic rule benders,
Machines that perform some or all of the as I mentioned earlier, do the bending and perform
“processing” functions (that’s final cutting, mitering, most or all of the processing functions of cutting,
and notching) and which also bend the rule, all mitering, and notching in a single machine. Well over
within a single machine, will be referred to as 200 of the automatic rule benders have been placed
“automatic rule benders.” in die shops in the United States since the
introduction of the fully automatic machines in 1997.
Finally, there are multiple station Worldwide, there are approximately 1,000 automatic
systems—systems which process on one machine and rule benders in operation. Just in the United States,
bend on another—sometimes bending is first, two to three new automatic rule bending systems are
sometimes processing is first. Since all of these being sold each week.
systems require individual pieces to be manually

Now, let’s get down to business: and when to use straight cuts, when to add run
through, when and how much to open or close bends
• How does the automatic bender work? and so on.
• How can it help your die shop become more Again, the automatic bender is a tool. And yes,
efficient and more profitable? it’s a very good tool. Some would even argue that it
• And finally, how does this translate into is the best tool ever introduced into the steel rule
improved diecutting operations. diemaking industry—even better than the laser. But
it still takes a knowledgeable person to operate it. A
The first step is to load the CAD file. Basically, person who is familiar with the basic principles of
the data from any CAD system can be utilized by any diemaking.
of the automatic machines. However, it is important
to remember the old axiom—garbage in, garbage out. OK. Now that we know what it takes to operate
A poorly constructed CAD file will not work well on an automatic bender, let’s look at what”s necessary to
any of the automatic rule benders. Gaps in lines, arcs produce the rule for our dieboard. Obviously, the
that do not intersect straight lines, overlapping lines, specific procedures and operations depend on the
poorly digitized files and files that have been type of machine being used. However, the operations
improperly converted from graphics programs such required to operate any of the automatic benders are
as CorelDRAW and Illustrator are some of the file very similar. First, select the starting point of the first
issues that will severely limit production and drive piece to be produced and the direction of travel.
your operator crazy. One company that sells Next, select the end point of this piece. Confirm that
automated bending systems has stated that 90% to the start and end points are correct.
95% of the problems that they see are related to the Now, assign a part name to this piece. The most
duality of the CAD file—only 5 to 10% are caused by common name is a sequential number—1,2,3,4 and
the machine, the die, the steel rule, and all of the so on, but it can be anything—Tom, Dick, Harry. In
other things in the diemaking process that can go some cases, the computer will automatically assign a
wrong. Obviously, a good CAD file is a critical sequential part number to the piece.
requirement.
At this point, the computer needs to know a few
Once you have loaded the file, it appears on the things about this piece—specifically, how many of
screen of the bender. From this point forward, think these pieces are required, is there a miter or straight
of the automatic bender as just another diemaking cut on the starting end of the piece, and is there a
tool. miter or straight cut on the outer end of the piece.
The machine replaces the manual portion of On one particular machine, entering an “N” in the
diemaking with mechanical, aids—electric, “type of cut” box will cause the machine to produce
pneumatic and hydraulic. The computer interface a straight end cut while placing a “Z” in the “type of
with the CAD system provides all of the dimensional cut” box will cause the machine to produce a mitered
and numerical data. But it is up to the diemaker to end cut. At this point, the information is confirmed
tell the machine what to do—where to break the rule, and the piece or pieces can be produced.
where to start and stop each piece, when to use miters

In hand you will have your final piece, cut, All that’s left is to cut and insert the score rule,
mitered, notched and bent, ready to go into the add the rubber and the die is ready to run.
dieboard. You can then go ahead and set up another
piece—select the start point and direction of At this time, I’d like to answer some of the
travel—select the end point and confirm—name You more frequently asked questions about automatic
may be asking yourself, what happens if the part benders.
doesn’t fit? And, to tell you the truth, not every 1. What type of productivity improvement will
part will fit as it comes off of the machine, I see with an automatic bender?
although the vast majority will. This is somewhat dependent on the type of work
All of the machines have some physical you do and how well the type of bender you buy fits
limitations. For example, some machines can the work that you do. And, let’s not forget the
produce sharp bends of up to about 1.25 degrees on current efficiency of your shop—the kind and
2 point rule. This means that bends of more than 125 condition of your hand tools and the experience and
degrees will have to be finished on a hand bender. skills of your diemakers.
However, the machines also give you the ability to But, productivity improvements of from a
make corrections to pieces which, for one reason or minimum of 2 to 1 to as high as 6 to 1 have been
another, do not fit perfectly into the dieboard. documented by current users of automatic bending
On one machine, any line can be lengthened or systems. The average is in the range of 3 or 4 to 1.
shortened by any amount. Any arc or sharp bend can Again, there are numerous variables to be
be bent more or less. Either of the end cuts can be considered, and what is true in one shop may not be
extended or shortened. A simple click of the mouse true in another. However, the worst case is that you
will produce a mirror image—right/left, up/down, would at least double your productivity.
however you refer to it. On the typical folding
carton or corrugated die, 95% or more of the pieces 2. Am I limited to a particular brand or type of
should go directly from the machine to the die steel rule?
without any adjustment or hand work. The balance
of the parts will require some hand work such as Absolutely not, All of the machines can be
angle grinding joints and finishing bends that were calibrated to run any brand and almost any type of
beyond the machine’s physical limitations. On other rule. However, a word of caution is in order. The
types of dies, especially those with a lot of quality and consistency of the steel rule are much
relatively small “freehand” shapes, the percentage more important in automatic machines than they are
of pieces requiring adjustment and hand work will when using traditional hand benders.
be higher. A very worst case would be where 70% When a machine has been calibrated to apply a
to 75% of the work is done by the machine leaving certain amount of pressure to generate a specific
25% to 30% of the work to be done with traditional bend, it will always apply that amount of pressure
diemaking tools. This would be more typical of for that bend. If the rule hardness is not consistent
jigsaw puzzle dies and work of this nature. from coil to coil or from batch to batch, the same
pressure will obviously produce a different bend.

3. What is the training period? Is it better to • Everyone wants everything now. Service cycles
start with a diemaker or a CAD operator? Or, is it have been shortened to the extent that almost
possible to use someone with no diemaking every job is a “crash and burn.” During the past
experience? few years “just in time manufacturing” has
become a common expectation.
The training period will vary but, in all cases,
will be relatively short—a few days to learn the Until the introduction of the automatic benders,
basics, followed by a few weeks of gaining the common approach was to go into the “panic”
experience, confidence and speed. In my opinion, it mentality or to tell our customers that they couldn’t
is better to start with a diemaker—someone who get what they wanted when they wanted it.
knows how dies go together, someone who knows
how to set up and bend by hand when necessary, Now there is a technological solution. Bending
someone who knows how to use a grinder in a safe times have been reduced by 50% to 80% or more.
manner—in other words, a diemaker. The knives can be prepared while the dieboard is
being cut. Reknifes are a piece of cake. Pull up the
It certainly doesn’t have to be your most previous job file and hit the run button. If a job is
experienced or highly skilled person, although it may smashed on press, pull up the job file and run the
be. A diemaker who has had some CAD training pieces that are needed. The press can be back up and
would probably be an ideal operator as they could running in minutes instead of hours.
more readily identify and fix file problems, but
people with those credentials are hard to find. And it It’s difficult to place a dollar value on cycle time
is still always better to find and fix file problems reduction, but we know of many companies who
before releasing the file to the diemakers. have been able to increase their volume significantly
because they could turn out jobs in a much shorter
Obviously, it would take much longer to train period of time than the competition.
someone with no prior diemaking experience.
• The use of automatic bending machines has
4. What are the primary benefits resulting from improved both quality and consistency. Joints are
automatic benders? tighter; bends are more accurate and more
consistent. The skill level of the diemaker
Again, this will vary greatly depending upon your becomes much less of a factor. Rework has gone
specific circumstances. However, following are some down. Diecutters have been able to document
of the things we have heard from people using this lower makeready times with dies produced on
technology: automatic benders.
• I can no longer hire highly experienced, highly • Costs certainly come into the picture as another
skilled diemakers. Further, I don’t have the time advantage associated with automatic bending.
and resources required to train new diemakers. Think about your shop. What would it mean to
The automatic benders have enabled my less you if the same crew of diemakers could produce
experienced, lower skilled diemakers to be much twice as much work; or if it only took half as
more productive—even more productive than my many diemakers to produce the same amount of
best diemakers who are using traditional work? This would certainly help to offset the
diemaking tools and equipment. And, I can train increasing cost of materials, the higher labor rates
persons with no prior experience in a much we’re all faced with and the higher costs of
shorter period of time. benefits such as health insurance.

Maybe it would provide you with some additional All that’s left is to cut and insert the score rule,
capital to expand the business. In addition to the add the rubber and the die is ready to run.
obvious cost advantages resulting from higher labor
efficiencies, there are also other cost savings such as Again, I encourage you to talk to the vendors who
less scrap—as much as 75%; the savings resulting will be happy to work with you to find a solution to
from lower makeready times and less makeready your specific problems and needs.
waste on press; how about the medical costs
associated with the shoulder, arm and hand problems Ed. Note: This article was adapted from materials which were
attributable to manual bending; space requirements submitted as part of 2001: A Diecutting Odyssey programming.
are much less; the costs associated with hiring and
training additional people when your business
grows—the list goes on and on.
As a very successful businessman once told me,

the key to his success was very simple. “Hire good
people, treat them well and maintain a clean and safe
working environment. Then, give the people the tools
they need to outperform the competition. To do it
better; To do it faster; To do it cheaper. Success is as
simple as that.”

CHAPTER 10
MAKEREADY
General Information Regarding Makeready Systems
In-Press Makeready Techniques for Automatic Platen Presses

Note: This article reprinted from IADD’s The Cutting Edge.
Machine set-up time or “makeready time” has ! Utilizing the new innovations in press design,
become an increasingly critical part of total production such as centerline register and outside-of-
cost. As diecutting runs become shorter, make ready press jigs for setting, stripping and blanking
time grows to be a greater percentage of total production tools.
time.
To help understand the many makeready related
topics as widely discussed in trade literature and
In-Press Makeready
advertising material, makeready can be divided into two Certain functions of the makeready process cannot be
phases, pre-makeready and in-press makeready. accomplished outside the press. It is highly unlikely that
a new press design, either now or in the future, will
eliminate the need for some type of in-press makeready.
Pre-Makeready In-Press Makeready is largely composed of
In the past, most preparatory operations were done in a accommodating the deviation present to achieve the
standing press. Machine set-up is still done that way in parallel and flatness needed for an even cut. The
many operations. During the last few years a great deal deviation in a press comes from a number of sources.
of energy has been expended and much progress made
in pre-make-ready. The pre-makeready process ! The unique “footprint” of the machine, which
represents a significant opportunity to influence the time expresses itself in apparent hills and valleys in
spent to get an automatic platen press into production on the platen surfaces.
a new job.
Some examples of time-saving pre-makeready ! The variation inherent in the die itself. It is not
techniques are: unusual for a completed die to present a surface
that is .005" (.12mm) out of flatness.
! Preparing the spot sheet by CAD, with the die
program. ! The unique deflection pattern caused by using
each new die in the machine.
! Using a pre-makeready press, such as Bobst
Easy-Press or the Meurer Pre-Makeready Press Any improvement in the area of In-Press
to set counter, make samples, etc. Makeready should conceivably save time and allow for
more uninterrupted production during the run.
! Setting-up of stripping and blanking tools by The ultimate craftsman may be able to produce
diemakers or specific pre-makeready personnel. a very serviceable makeready with conventional
practices. Obviously, not all operations are functioning at
! Establishing a “Pre-Makeready Department” a level that will produce the best makeready.
separated from the diecutting press.

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In-Press Makeready Techniques for Automatic Platen Presses
A makeready product should yield a repeatable, Benefits:

standardized outcome. It should add a degree of One insert can be used for many jobs and it can
predictability to the process. Several systems and remain in position for two or three months.
products are readily available to address this need. Enhanced score definition is possible.
Best results are obtained in press formats below
What is Available? 40" (1M), on simpler forms.
The following products are currently in use in the U.S.
at this writing. Liabilities:
Elastomeric inserts will require from 20% to
35% more pressure than is normal to perform.
The AUTOCUT(R) System.
The additional pressure causes more wear on
The AUTOCUT System is a plastic coated photo
press parts and dies, over time.
polymer plate (.044"/1.1mm) which has the consistency
Maximum compensation approximately .005"
of candle wax. This plate is inserted into the diecutting
(.12mm) -- (not the answer for complex dies).
“sandwich,” and as the pressure is increased, the
material levels the form. After optimum leveling, the
Other Makeready Aids.
plate is hardened by U.V. light.
Several other products have been mentioned recently
which seem to be designed to address the In-Press
Benefits:
Makeready problem. At this time, however, there is
The most precise makeready.
only a limited amount of information on them. When
Fewer stops during run.
more information is available, including production
Better die life, longer cleaner cutting.
experience, these items can be reviewed more fully. The
Wilson-Tyler spot sheet cover is a .029" semi-rigid
Liabilities:
sheet of plastic. It replaces the spot sheet cover. The
Must use one plate for each die.
Not cost effective for simple dies, on short runs “Compensation Foil” as described by Jurgen Marian of
where length of die life is not an issue. Cito, is a plastic sheet (.020") which must be installed
between the back of the die and steel chase back.
The Elastomeric Inserts.
The elastomeric inserts share a number of qualities: Do These Products Work?
they are inserted into the diecutting “sandwich,” either Whether any individual product “works” is a complex
behind the die or under the cutting plate; they will lose question. Each product has a set of physical properties.
their elasticity over time but can function as a shock It acts the same way all the time. The Autocut plate gets
absorber to save spot up; and they can enhance scoring hard; the SpotSaver or the Ez-Kut compress on
definition because of the “dwell” effect. The pressure. Whether the use of any of these systems will
SpotsaverTM by Atlas Die is a .040" (1.0mm) stiff mat. produce the benefit envisioned by its designers, will be
It is used behind the die or under the cutting plate. The determined by the users.
EZ-KUTTM Insert by XPI is a .040" (1.0mm) flexible When, and if, an operator sees the possibilities
sheet. It is for use only under the cutting plate. of using the product as a tool, and adopts it into his
routine, he will come to the conclusion that “it works.”
And it will!

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The One Hundred Year Problem...

LCC Mat, A New Concept ... to Reduce Cutting Press Set-up Time
Eliminating Patch-up Sheet in Platen Diecutting.
Note: This article reprinted from IADD’s The Cutting Edge.
For the past 100 years in platen diecutting, the process.

traditional method of steel rule diecutting onto a hard The LCC MAT is a patented mat that is placed
steel cutting plate has required a procedure called under the chase plate against the platen of an automatic
makeready or patch up. Theoretically, if the distance platen press or under the cutting plate of a manual platen
between the top and bottom platens of a cutting press are press. It acts as a compensator that can eliminate any
perfectly parallel and the die blades were all exactly the unbalanced conditions in the cutting press or differences
same height then no “patch-up” or make ready should in height in the blades of the die. The mat can be used
be required to obtain a perfect diecut. over and over again from job to job. It too sounds too
In reality, there always tends to be some degree simple to be true, but it works.
of unbalance in a cutting press. The top or bottom platen It is claimed that by using the LCC MAT that a
of a press may have been worn in usage, the head of the diecutter can:
press may be out of balance or the cutting die blades
may not be perfectly flat or the same exact height. The # eliminate makeready and the patch up sheet
result is that some sections of the die blades in a die do # provide sharp scoring which will improve
not cut through the all the material being diecut to automatic folding and gluing operations
provide a perfect diecut. A patch-up sheet with spot-up # minimize paperboard dusting and flaking
tape compensates for low spots. The patch up sheet # obtain longer die life
builds up those areas so that a perfect diecutting # use the LCC MAT on both automatic and manual
situation can be obtained. This process can involve feed platen presses
considerable time and effort in many cases especially # save valuable time and minimizes cutting press
with complicated die layouts. The process is expensive downtime.
and reduces productivity. There are various methods in
use today to compensate for uneven platen surfaces, The concept was developed by Hidemaro
unbalanced conditions on a platen press or slight Yamada, President of Yamada Steel Rule Die in Japan.
variances in the height of blades in a steel rule die. The system has been developed and refined so that today
These methods all have one common problem, they take many automatic platen and traditional platen die presses
time to accomplish a perfect die cut and they keep a in Japan operate without any time wasted in the
cutting press out of production during the makeready makeready process. A simple explanation of this process
process. is to assume that there is a 0.1 mm (0.004") height
difference between the different sections of blade in a
THE LCC MAT SOLUTION steel rule die. The mat absorbs energy in every
There had to be a better more efficient and simpler way impression and then returns to its original condition.
to solve the problem of lost productivity in the The condition which compensates for variations in
makeready process. There had to be a simple method platen parallelism situations and variations in die blade
that could cut down on down time during the set-up height is the “Dynamic Balance Condition.”

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The One Hundred Year Problem...

INITIAL BALANCING OF A CUTTING place the LCC MAT under the chase plate. Under the
LCC MAT place a 0.07mm (0.003") sheet of Kraft
PRESS TO USE THE LCC MAT paper along with a sheet of carbon paper. Cut off one
The LCC MAT can automatically compensate for corner of the LCC MAT so that you can realign the
variations up to 0.3mm to 0.4mm (0.0115" to 0.0155"). paper in the same location if removed during the test.
The LCC MAT is 1.0mm (0.0395") thick with a Preferably use a multiple cavity cutting die that has
thickness tolerance of +/- 0.05mm (0.002"). Normally enough blade area to provide a good distribution of
a new cutting press will have a flat cutting base with blades over the entire cutting area of the press area.
perfect parallelism between the upper and lower platen. Make the first impression using the minimal pressure.
Normally after a year of operation it is typical that wear Increase the pressure on subsequent impressions until
on the cutting base may form some slightly low areas in approximately 60X of the paper board shows
one area of the base plate depending on how cutting dies impressions from the die. This may take several
are normally mounted on the die press and how the impressions at different pressure settings. In the case of
press is operated. a manual platen press, the Kraft paper would be under
If a new LCC MAT is used directly on an the cutting plate.
unbalanced cutting press, it is possible that inferior Once approximately 60X of the die cuts, you
cutting results will be obtained. For example, on an should be able to notice an area where the paper board
unbalanced platen cutting press, the gripper side of the marked. This area is a low area. Take a ball-point pen
chase could be 0.3mm lower than the opposite side and outline this area. This area is the area where you
which could result in the paperboard on the gripper die need to permanently create a patch. Cut out this area
not cutting completely through. Before a new LCC from the Kraft paper sheet and then glue it to the
MAT is installed it is recommended that a simple one underside of the chase plate. You can align the patch
time test is made to indicate where any possible low sheet by using the original Kraft paper sheet. You have
wear points may be located on a cutting base plate. not compensated for the main low point of the platen.
Your LCC MAT is now ready for normal diecutting and
PERMANENT WIDE AREA PATCH will provide compensation without additional patch up
This test is relatively simple as explained in the Bobst work. Write down the dial gauge pressure so that you
seminar text D3/5-1 and D3/5-2 to create a permanent can use the same pressure on the next order.
wide area patch up sheet. On an automatic platen press,

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Directions for Using the Spot-LessTM Blanket

Note: This information written and provided by The Wilson Tyler Group, Kenosha, WI.,USA
1. Position the Spot-Less Blanket on top of a blank spot sheet.
2. Adjust the thickness of the spot sheet cover (protector) to accommodate the
.030" thickness of the Spot-Less Blanket by replacing the spot sheet cover
with sheet(s) of aluminum, steel or plastic totaling .030" less the original
spot sheet cover.
OR
Adjust by any other means that will save .030" space behind the die and not
interfere with normal operation of the cutting machine.
3. Lock the chase and proceed with the normal makeready. Begin to adjust the
cutting pressure by bringing the press to approximately 70% of cutting.
Next, increase the cutting pressure one or two thousandths at a time and
pull a sheet after each adjustment. As you increase the cutting pressure,
observe the areas which are not cutting satisfactorily. Following each
adjustment, if there is an improvement in the unsatisfactory areas, you
know that the blanket is doing its job. You must SQUEEZE the blanket for
it to do its job. When you get close to 100% cutting and an adjustment does
not improve the cutting in any area -- STOP! Back off the cutting pressure
one half the amount of the last adjustment and spot up any areas that need
it. The pressman must determine the exact point to stop increasing the
cutting pressure. After one or two uses of the Spot-Less Blanket, the
pressman will know exactly how far to go, depending on the die
configuration and condition, and the stock to be run.
4. Any additional spotting can now be done in the usual manner.
5. The Spot-Less Blanket will maintain the quality of the spotting makeready
for the entire run.
6. When the job is finished, remove the die and spot sheet and install the next
die following the same procedure. Other than a new spot sheet, no further
adjustments to the Spot-Less Blanket or the cover material are necessary.
When the cutting pressure is released, the Spot-Less Blanket will return to
its original .030" thickness.

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Converters Bid Farewell to Makeready Hassles
Note: The following adapted from material provided by Atlas Die, Inc., Elkhart, IN.,USA
Over time, the converting business has changed Today’s solution

dramatically; from low to high technology, from Atlas’ patented pending SpotSaver™ mat has been
drawing boards to CAD systems, and from jigged to introduced successfully to customers worldwide,
laser produced steel rule dies. Yet, until recently, the substantially reducing their press down time and
painstaking task of makeready spot-up has changed little increasing productivity.
over the last 100 years. - Until the introduction of The SpotSaver™ mat can work in tandem with a
Atlas’ SpotSaver™ mat. spot sheet. Special requirements for success are simple;
The platens must be close to parallel. Over the next 100
The past challenge years the savings could be astronomical. How will you
In the past traditional platen steel rule diecutting spend all that money.
required extensive spot-up makeready time. Today,
unbalanced cutting presses and knives of differing Installation, training simplicity
heights are typical. Platens worn from usage are SpotSaver™ means simplicity. Higher knives are lowered
common. Time spent on extensive spot-up has been a and - with balanced pressure form the SpotSaver™ mat -
tedious and expensive procedure. The name, “spotting the system levels the cutting knives increasing their
up”, refers to a spot sheet behind a die or under the cutting accuracy. Cutting can then be brought up to the
cutting plate that is patched to produce matching knife 90-95% range quickly, which will reduce makeready
heights. The technique requires raising the low knife time by reducing overall spot-up. All training is done by
areas to match higher ones through use of spot sheet and transferred information and the support of the Atlas
shim tape that eventually produces matching knife technical sales people. Like the three minute installation
heights. Cutting with consistently even knife heights of the mat, training is short.
would produce nearly 100% cutting accuracy - and
increased profits.
Benefits:
9 Eliminates 2/3 to 3/4 of all spot-up makeready time
9 Quick and easy installation in 3 minutes or less - Attaches to back of chase
plate, under the cutting plate, or directly over the spot sheet.
The spot sheet allows for a combination makeready option
9 Sharper scoring and creasing due to increased impact
9 Cost effective
9 Extends cutting rule life
9 Reusability: 30 jobs or more
9 Adaptable on same size presses
9 Versatile: works on Bobst, Zerrand or other automatic platen die cutting
presses and manual feed cutters.
9 Minimal paperboard flaking and dusting
User Note:
Platens must be parallel to ensure success. A platen press must be leveled within .15 mm
or approximately .006" to attain best results. Depending on specific needs, a combination
makeready consisting of the SpotSaver mat and a spot sheet may be used.

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Name Manufactur Operation Working Composition Thickness Thickness

er Shore U.S. Metric
Hardness
AUTOCUT(R) X-Print, Inc. Molded by 95 “A” Photopolymer 0.044" 1.118mm
System pressure, over
hardened by aluminum
UV curing
EZ-KUT(TM) X-Print, Inc Elastic shock 70 “A” Blended 0.040" 1.016mm

Insert absorber, polyurethane
job after job
SpotSaver(TM) Atlas Die, Inc. Elastic shock 70 “A” Blended 0.040" 1.016mm
absorber, polyurethane
job after job
Spot-Less(TM) Wilson Tyler Replaces spot Not Available Not Available 0.045" 1.12mm
Blanket Cover Group, Inc. sheet cover; to to
sized to 0.158" 4.0mm
accommodate
individual
machine
specifications
NOTE: For additional product information contact individual manufacturers.

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CHAPTER 11
CLICKER/HIGH DIES
General Information Regarding Clicker/High Dies
Clicker/High Die Terminology

Clicker/High Dies
This type of die is manufactured from special shock 3. Clearance Wall (a.k.a. clear thru) - is especially
resistant, Chrome/Moly Alloy steel which is basically relieved to allow cut parts to come out the back
soft when supplied to diemakers in long bars. of the die. Needed, for the most part, when
“Benders” bend the bars to fit the customers cutting rigid, non-flexible materials.
pattern or blueprint. After the die has been “bent” to
the pattern, it is hardened in a heat treating furnace to
make it durable and long lasting. These dies are
commonly called “clicker dies” or “forged dies”.
Clicker/High Dies can be “bent” in three
different ways to effect the best cutting.
1. Regular Wall (a.k.a. regular bend) - is normal

bending with no attention paid to what happens
to the back of the die while fitting to the cutting Die Steel Heights and Thicknesses
edge. This sometimes makes the die “tight” on
the inside. Most dies are bent this way and will Single & Double Edge Blades
successfully cut, for the most part, all soft and 1. Standard heights of steel are: (Figure A)
pliable materials. US: 3/4", 1-1/4", 2", 2-1/4", 3-1/2";
Metric: 19 mm, 32 mm
2. Standard thickness’ are: (Figure A)

US: 1/8", 3/16", 1/4";
Metric: 3 mm, 4 mm, 5 mm
3. Single edge dies can be made in all heights,

while double edge dies (Figure B), have a
cutting edge on both sides is available only in
3/4" height. A double edge is used where right
2. Straight Wall - is relieved slightly so material and left parts are needed. By simply flipping
does not stick in the die. The inside wall of the the die over on the block, the die will cut the
dies are nearly perpendicular, thus the name mirror image of the desired part.
Straight Wall. They are frequently used to
prevent undercutting on stacked materials.

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Definitions
CLICKER BLOCK - A cutting surface that a clicker or CLICKER PAD - Disposable “into” cutting surface of
high die cuts “into” on a hydraulic cutting press. various materials such as composition rubber,
Clicker blocks come in two varieties: (1) A block of polypropylene, nylon or hard pressboard.
laminated sections of composition rubber or
polypropylene 3" thick with irons to hold the block CLICKER DIE PRESS - A single arm press usually
together. (2) A 1" or 2" composition rubber, with cutting bed, up to 20" x 40" in size, on which
polypropylene or other material mounted onto a hard clicker dies, bolted steel rule dies or ordinary steel rule
wood base. dies are used. The name “Clicker was derived from the
clicking sound made by the mechanical action when the
CLICKER DIE - A forged or pre-ground die used flywheel was released to initiate the downward cutting
primarily on a clicker press. A clicker die is normally action on early non-hydraulic presses like the USM Ideal
made in heights up to 1 1/4" high with a blade thickness Clicker dating back to 1906.
of 1/8", 3/16" or 1/4". The blades are free standing
with no center wood for support but may be reinforced HIGH DIE - 1. Die made higher than standard cutting
with braces and a backplate welded on to the dies so the rule heights. 2. A forged heat treated die, also referred
die can be rubber loaded for ejection of the diecut parts. to as a dinker or walker die, normally over the height of
1 1/4" made of 1/8" through 1/4" thick steel. This die
CLICKER PRESS - Generic term now referring to all can have many options of die blade construction to cut
swing arm diecutting presses used in much of the soft various types of materials.
goods converting areas.
Tubes and Punches for Hole Cutting
Punching holes in conjunction with cutting can be facilitated by use of tubes (a.k.a.; hole punches).
Three basic tube mountings available:

1. Drive Tube -- usually used for routed solid milled clicker dies, fancy & machined dies, but
can also be utilized in clicker dies.
Tubes are available in single & double edge in decimal sizes.
2. Shoulder Tube - most commonly used in clicker dies. Back of tube easily cleared
for scrap ejection.
3. Screw Tube - very useful where easy removal of tube is necessary.

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Clicker/High Die Types

Die Steel Die Type
Height Thickness
3/4" 1/8" Single & Double edge clicker die -- hardened all over
3/4" 3/16" Single edge clicker die -- hardened all over
3/4" 1/4" Clearance die, forged steel or clicker die -- hardened all over
1-1/4" 1/8" Open Clicker die -- hardened all over
1-1/4" 3/16" Open Clicker die -- hardened all over
1-1/4" 1/4" Straight wall forged die; or regular wall clicker die -- hardened
all over
2" 3/16" Straight wall forged die; or regular wall clicker die -- hardened
all over
2-1/4" 1/4" Regular wall backplate or open die -- hardened all over
3-1/2" 1/4" Walker die or high die -- clearance or back plate -- hardened all
over
19 mm 3 mm Flex die -- single edge & double edge -- prehardened steel
available
32 mm 3 mm Prehardened steel die
19 mm 4 mm Serrated rule prehardened die

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Clicker/High Dies
Standard Tolerances for Clicker/High Dies

Die Type US Metric
Tolerance Tolerance
The general standard for most clicker dies, high dies, etc. +/- 0.015" +/- .38mm
Machined clicker dies +/- 0.010" +/- .25mm
Routed solid milled clicker dies +/- 0.005" +/- .13mm

11-4A
The Care and Maintenance of Clicker and High Dies

Note: Excepts from an article published in DDIN International
Written by Jerold Larson, President, Pioneer Die & Trim Systems, Ltd.
CHECK IN PROCEDURES fixed in one location and the die cuts “onto” or against a
1. Check Specifications & Tolerances hardened steel cutting plate. The only danger is if the
2. Check Die Identification Markings height control on the die press is not properly adjusted.
3. Store Dies Properly Then the die edge can over drive into the cutting plate
causing damage to the cutting edge of the die and/or
permanently marking or damaging the cutting plate.
CUTTING DIE CARE DURING USE
The basics of good die cutting are: 2. DIES STUCK INTO CUTTING SURFACE:
1. Use cutting dies that are properly maintained in a There are times when a die may get stuck in a cutting
sharp condition surface. If it is necessary to force a die out of a cutting
2. Use cutting dies that are in good repair surface, use a rawhide mallet or a plastic tipped hammer.
3. Insure that cutting surfaces or cutting plates are Never hit a die with a metal hammer!
well groomed and flat
4. NEVER OVERLOAD A DIE. Cut only as much 3. USING CUTTING DIES LARGER THAN THE
material in one diecut as the die is designed for, CUTTING HEAD OF THE PRESS:
otherwise one can overload the die and cause it to Some die failure is caused when large dies are improperly
“explode open.” used on smaller presses. This is very common on clicker
type machines when an operator is die cutting with a die
Several factors can eliminate die problems before they that is larger in area than the head of the cutting press.
begin. Consider the following factors: As an example, a diecutter has to diecut a large
piece that is 32" long and the head of the press is only 16"
1. IMPROPER CUTTING PAD USAGE: or 24" wide. The operator then has to move the head over
Distribute cutting over the total area of the cutting surface. one end of the die and make an impression and then swing
Do not use only the front center portion of the cutting pad. the head of the machine to the other end of the die and
After extended use, the cutting pad is worn away and make another impression. This practice results in making
causing an uneven surface. This creates a strain on the die the die bow (quite like a banana) and creates strain and
and requires more pressure to get a clean cut. Repeated possibly die breakage.
cutting under these conditions can cause the die to become
warped out of shape and it could break. 4. HITTING A DIE WITH A GLANCING BLOW:
Only a minimum amount of penetration is required Another reason for die breakage is catching the die with a
for efficient clean diecutting. If an operator needs to dig his glancing blow. This happens on single post swing arm
die deep into a cutting surface, this indicates that either the clicker machines when the operator trips the beam while
cutting edge of the die is dull, that the cutting surface is not the head of the press is being swung over the die. The
in the best of condition, or he is using the wrong cutting result is that the die is hit in an angular downward
pad material or hardness. direction. The correct method is to bring the upper arm of
If an “into” cutting surface wears out too fast and the press over the die and then trip the press. This also
the dies are not dull, that is a good indication that the occurs with traveling head presses when an operator is
wrong hardness of cutting surface is being used. In that moving the head of the press over the die and initiates the
case the operator should try another type cutting pad downward movement of the head before the moving head
material or hardness. of the press is located squarely over the die.
In most steel rule diecutting, the die is permanently

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The Care and Maintenance of Clicker and High Dies

5. SELECTION OF A “SITTING SPOT”: MAINTENANCE OF DIES

It is often necessary to lay the die down for a while. It is
important to have a “Sitting Spot” for the die while it is SHARPENING DIES
not in use. This is important so the cutting edge can be Clicker and high dies can be re-sharpened many times to
protected to avoid nicking and dulling, and prevent the extend their working life. Care must be taken to maintain
die from being accidentally dropped. a flat and parallel condition with the back of the die.
A carbide tipped, hand held, cutting die dresser is
6. IMMEDIATELY RETURN DIE TO IT'S available. It can be used to redress the edge of a die
STORAGE AREA: effectively in the cutting room. It is a useful for a quick
After a diecutter has finished with a particular die, the die emergency “fix.”
should be returned to its original storage area and not The ideal situation when dies require resharpening
allowed to lie around in the cutting area where it could be would be to return them to a die manufacturer for a
damaged. If the dies require sharpening or repair, they complete reconditioning. An alternative is to have the shop
should be taken out of service and immediately fixed. personnel attend a training session to learn proper
maintenance procedures such as welding, edge hardening,
STORAGE OF CUTTING DIES grinding, and sharpening.
Store a set of dies with the identification markings clearly Generally, steel rule dies are not re-sharpened. It
visible. Dies should be stored in an area that is accessible would be better to have new blades put into the dieboard or
to the die presses. Also, the dies should be stored in an replace the die.
area that is dry and away from moisture. When dies are
stored for a long time, it is best to give them a light coating REPAIRING BROKEN OR DAMAGED DIES
of oil or some sort of preservative like WD-40 to prevent One major error that some people do is to have the die
rusting. temporarily brazed with bronze. Never braze a die to
Dies can be mounted on a pegboard or repair it. An all steel die should always be welded and re-
shadowboard according to die number and shape. tempered.
Dies can be placed into drawers for easy retrieval,
but, make sure the drawer is only deep enough for one WHY DID THE DIE BREAK?
layer of dies. It is a good idea to line the drawer with a
layer of felt or some other soft material. Ask the following questions:
Another excellent storage method is to build
vertical shelves in a rack so the dies can easily slide into Was the die used properly?
their respective slots. Each rack can contain a full set, Was the cutting surface in good repair?
style, or size run of dies. It may be convenient to put
wheels on the racks for easy transportation to the cutting Was the die pushed beyond its capabilities by trying to cut
stations. If the rack is on a “lazy Susan,” die searching is too many layers of material at one time?
less of a chore. Did the die give way due to a manufacturing fault of the
If cutting dies must be stacked, put cardboard or die?
wood slats between them and limit the stack to two high.
Was the type of material being cut changed?

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CHAPTER 12
ROTARY DIECUTTING
General Information Regarding Rotary Diecutting
Note: This article was written by Ray Pfaff
Bernal International, Inc., Rochester Hills, MI, USA
Introduction: 1960’s, technical problems prevented its general

As an alternative to the long used and accepted steel acceptance as a viable manufacturing system. RP
rule cutting dies that are employed in reciprocating (rotary pressure) blade configurations were
motion machinery, rotary dies offer a higher speed employed by American Can on the wrap around
option to paper converting operations. Available in plate, however, after its patent expiration, this type
a number of differing forms, the rotary die user of cutting blade was popularized by Bernal Rotary
must choose the type of rotary die that best suits the Systems on solid EDM (electrical discharge
application. Although, until recently rotary dies machining) dies. Subsequently, the 1990’s saw a
were available on a “one size fits all” basis, the revival of the wrap around plate rotary die with the
current offerings are representative of a new wave advent of the magnetic cylinder mounting system
of applied technologies. and improved chemical etching technology.
Rotary cutting dies have been used as part of Atlantic Eagle Corp. brought the journal-less
the printing and converting industry since the late innovation to rotary dies in the early 1990’s and
1940’s. The first significant application was the merged that technology with its merger into Bernal
“Ex-Cello Pure Pak” milk carton (sometimes International, Inc. in 1997. Bernal International,
known as the gable top milk carton). Followed Inc. announced laser heat treating and laser clad
shortly thereafter by the Mark Andy applications of blade forms technology shortly thereafter. These
rotary tools for the production of the pressure newest technologies make rotary very cost
sensitive label products. The milk carton rotary competitive and justifies applications to small
tools were a plurality of segments that were volume runs. Rotary cutting dies are justified
assembled on the surface of a ground cylinder to primarily because of their superior speed of
form a pattern of nested carton blanks. The pressure operation and the resulting increased throughput /
sensitive rotary tools were much smaller and productivity.
operated with bearers so as to allow partial cutting
to a liner material. Rotary Dies are Divided into Two Types of
The next milestone in the chronology of Cutting Technologies:
rotary die development took place in the late 1960’s
when Bernal Rotary Systems received patents for Crush Cut
the manufacture of solid rotary dies from fully This type of rotary die cutting utilizes a knife like
hardened steel materials. This represented a viable cutting element that is very similar to steel rule
option for paperboard converters to use rotary dies except it is machined onto the periphery of a
for jobbing type converting in the general folding cylinder. The material is separated by wedging
carton industry. Die life, and relatively quick action when the knife blade is impressed into the
change over was now possible. material, which is supported by an anvil cylinder.
Although the wrap around plate concept was
developed by American Can Corp., in the late

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RP isolating the bearings and retainers from the product

This type of rotary die (rotary pressure) utilizes a dedicated tooling cost.
square faced cutting element to perform a shearing Generally speaking, solid rotary tools,
type of cutting against a mating cylinder. The produced from a single (solid) cylinder of steel, will
material is separated as a result of the pressures operate at higher operating speeds than the wrap
exerted by the upper and lower cylinders co-acting around types. Speeds of more than 300m/min. Are
to effect a material separation. frequently achieved with rotary tools. The primary
limitations to speed are the stripping of scrap and
parts delivery.
Product quality for packaging applications is
improved when rotary dies are used as a result of
the superior machining tolerances which create a
cleaner cut edge and significantly more uniform
crease definition. Additionally, no “nicks” are
required to deliver a rotary cut package blank.
Cavities to cavity deviations are eliminated when
rotary dies are used.
Recent technological improvements have
made it possible to manufacture rotary dies that will
be cost justified for low production volumes on a
basis similar to flat bed steel rule dies. Laser heat
This diagram shows the edge view of the web after treating and metal cladding have broadened the
being cut with RP and Crush Cut technologies. application of rotary or continuous motion
Note how RP causes a slight warping of the
material being cut on either side of the blades. processing to include paper, non-woven, pressed
Care must be taken during die design to ensure board, ferrous and non-ferrous metals as well as the
proper shingling, stacking and feeding through
side seam gluers.
full spectrum of plastics.
Product Descriptions and Information:
Both the RP and the crush cut principles can be Die Life:
applied through the use of wrap around plates. The Solid rotary dies can be re-sharpened about 3-5
wrap around plate concept requires that the cutting times. Clad tools can be renewed by re-cladding
elements are machined (usually chemically etched) (after the re-sharpening) an unlimited number of
on an essentially thin metal plate which is times. Wrap around plates cannot be re-sharpened.
subsequently “wrapped” around a mandrel cylinder. Tool life will vary significantly and is dependent on
Methods of attachment are both mechanical and the materials the tool is cutting.
magnetic.
Further, RP and crush cut types of dies as Machinery and Applications:
well as wrap around plates can be employed with Machinery is available that will allow rotary tools
the journal-less concept of die mounting. to be incorporated as an after market installation as
Journal-less rotary dies, no matter which cutting well as from the OEM press manufacturers.
type, will reduce the cost of the rotary tooling by Follower and electronic line shaft connections
IADD Product Information 12-1.112-1

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are regularly used. Rotary machines are regularly

being used as both in-line and off-line systems.
Specialty rotary systems often are complete
dedicated manufacturing centers.
Products that are currently being produced
with the use of rotary dies for cutting, creasing,
embossing, and assembling are extremely varied in
nature. Here are a few:
Film products
Sanitary products
Hospital surgical products
Medical products
Folding cartons and packaging products
Energy storage devices
Food products
Automotive electrical products
The application of continuous motion

manufacturing is used worldwide and includes End view showing continuous cut. Note offset top
virtually all materials available in roll form. (Coils). and bottom blade locations which produces
The market continues to grow for rotary/continuous shearing action.
motion manufacturing systems as all industries seek
more productivity and lower costs.
Rotary Pressure (RP)Cutting Principle

Upper and lower cutting edges on dies are precisely positioned to
shear substrate. Resulting edges are clean with very little fiber pullout.
RP Advantages
Cleaner cut product edges
No metal to metal contact
Longer wear cycles between sharpening
Stronger blade Geometry
More resharpenings (longer die life)
RP Disadvantages
Matched die sets are more expensive
More precise setup required at installation
More precise running adjustments required
More precise product stripping required
Side view showing separation cut. Note offset blade positions producing shearing action.

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TYPICAL CUT AND CREASE DIMENSIONS
CORRECT BLADE RELATIONSHIP

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The Rotary Pressure Cutting Technique/Process
Note: This information adapted from the Packaging Productivity, Vol.2 No.1.
What is Diecutting? The second part of the diecutting process is called

We have defined the diecutting press as a toolholder. explosive separation.
“Platen diecutting is a high speed, volume
manufacturing process, where web or individual sheets Platen Versus Rotary Diecutting
of paperboard are fed through a stamping mechanism in To understand the impact of the lateral force generated
which a number of male and female tools are positioned in platen diecutting, it is useful to compare the process
to accurately cut, deform, and press repeatable shapes to rotary diecutting. The Rotary Pressure Cutting
from paperboard.” System (RP) is a rotary web fed diecutting system. It
uses two units with upper and lower cylindrical
Simultaneous Cutting Force segmented cutting tools. The first unit is the creasing
When we refer to the manufacturing process as unit and the second is the cutting unit. The creasing unit
diecutting, we are in fact using incorrect terminology. performs similarly to the platen creasing process as the
We do not diecut paperboard. We compress the material paperboard is sheared between two surfaces by a male
until it bursts apart with explosive force. When the knife former (forming tool) to cause partial internal
first makes contact with the paperboard it compresses delamination in the formation of the bead. The cutting
and densifies the material while it simultaneously unit is quite different as there are raised surfaces or
stretches and stresses the surface of the paperboard. “lands” on the upper and lower cutting tools. The tools
The combination force and surface stretching do not contact each other and the paperboard is split
eventually bursts through the surface layers. This force under pressure from both sides by the accurate
is called explosive penetration. Once the surface is split relationship between upper and lower c utting land.
we are now using the two cutting wedge beveled faces Cutting is clean and dust free, and there are no nicks!
(of the steel rule knife) to push the material laterally
away from the knife edge until the material ruptures or
shears apart.
Rotary Pressure Cutting uses (Continued on next page)

incremental tooling. That is the
cutting process is only using part of The Rotary Pressure Cutting System (RP) is a rotary web
the tools at a time and the material is fed diecutting system consisting of a creasing and then a
incrementally cut. cutting unit.

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The Rotary Pressure Cutting Technique/Process
Simultaneous versus Incremental Tooling caliper, or moisture content of the paperboard has much
The difference between platen diecutting and rotary less impact on this process than the alternative platen
diecutting is how the tools work together. Rotary diecutting process. Why is that?
Pressure Cutting uses incremental tooling. That is, the The explanation is simple. In platen diecutting
cutting process is only using part of the tools at a time we are using a simultaneous cutting process. That is we
and the material is incrementally cut. To simplify the are cutting, creasing, scoring, embossing, debossing,
diecutting process further and to reduce the diecutting deflecting, and deforming the paperboard material all at
pressure required, the cutting and creasing tools are the same time. The disadvantages of simultaneous
separated into individual units. Another example of tooling are significant. Considerable rapid tool wear,
incremental cutting system would be a pair of scissors. high levels of difficult to balance cutting pressure,
In this example we are using part of the upper and lower significant material distortion, and any variation in the
tooling and are only cutting through part of the material density, the caliper, or the moisture content of the
at any time. The advantage of incremental tooling are paperboard will seriously undermine the quality and
significant. Limited tool wear, reduced cutting pressure, speed of output.
minimal distortion, and any variation in the density,

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for
Flexible Plate Dies
Flexible Plate Dies

Type Specification U.S. Metric Notes
Tolerance Tolerance
Folding carton Steel Thickness +/- 0.002" +/- 0.051mm
Folding Carton Board 0.010" 0.254mm
Caliper Range to to
0.033" 0.838mm
Folding Carton Cutting Capability 360o 360o
Continuous Continuous
without gap without gap
Label* Steel Thickness +/- 0.0001" of +/- 0.0025mm of
.016" to .024" die height required die height required
Label* Paper 0.001" 0.0254mm
Caliper Range to to
0.016" 0.4064mm
Label* Base Thickness +/- 0.001" +/- 0.0254mm
of requirement of requirement
*Label dies are attached to magnetic cylinders or with double sided tape.

12-4A
CHAPTER 13
EMBOSSING
General Information Regarding Embossing and Foil Stamping
Note: This information adapted from an article in DDIN - North America
Written by George Krim, President, Adolph Bauer Inc.
An embossing die is a tool usually made surface of the stock. In order to fulfill this action
from a flat metal plate. Once engraved, it is you will be required to provide the diemaker with
mounted in an embossing press and the paper or special instructions and information relative to the
board stock is pressed from the engraved areas of embossing.
the plate (or die) creating a raised impression on the
“Concerns” that must be addressed to successfully

manufacture an embossing or foil stamping die.
1. Art and/or mechanicals including a comprehensive “mock-up.”

2. The selection of paper or board stock.
3. Specifications, regarding the embossing “effect.”
4. Surface applications, before and after embossing.
5. Press production; form, size, method.
6. Printing and diecutting plus folding and gluing.
7. Monitoring and Quality Control (Special makeready procedures).
8. Scheduling and Cost.
The manufacturing of embossing and foil and after embossing or foil stamping, the length of
stamping dies, requires a highly specialized the runs, and the expertise of the people who will
planning system. Each design is an original; be using the die(s) or die systems.
requiring individual examination, the allocation of When the information gathering is complete,
explicit die manufacturing specifications, staging a schedule can be determined. Much probing is
procedures, the implementation of a work time- done so that all aspects of the job are exposed. Most
frame, an inspection cycle, and an ultimate proofing schedules for die work fall into the satisfactory time
session. Depending on the simplicity or complexity frame of “ten days” of needed production time.
of each design, a delivery schedule must be worked Such scheduling is acceptable and the standard in
out to the satisfaction of the customer. Our attention the industry.
must be spread out to encompass all facets of the The bottom line in Diemaking is, not so
job. We will ask about such things as; the stock(s) much “what kind of die is needed?” but rather,
that will be mounted; the use of heat in the presses; “what kind of an effect is desired?” Good and early
the kind of foil to be used, colors, hues, and communications will contribute greatly toward
coverage needs; the finishing of the product in making the die that accomplishes what the
terms of, folding, gluing, diecutting, laminating, customers desires.
coatings that may be applied to the stocks before What a “pay-off” when this occurs!!!

Note: This information provided by Cape Art Die, Inc.
EMBOSSING 3) Combination embossing: A combination die

Embossing is the raising of the surface of a stamps (transfers foil) and embosses with a
paper or board stock This is accomplished by means single pass on the press. This involves the
of a press (platen or rotary), an embossing die and production techniques of both a leaf-stamping die
a counter or male die. Embossing literally gives a (relieving the background) and the embossing die
third dimension and can greatly enhance the which “bumps up” or raises the areas that stamp.
finished printed piece.
The usual materials for an embossing die are Requirements for ordering an embossing die are:
brass, copper and magnesium The desired design is
cut into the metal by hand engraving, machine 1) A description of the image to be reproduced ie:
engraving or photoetching with an acid. type of die, depth, bevel of edges, any texture or
special effects required.
The types of embossing are:
2) The artwork, usually in film or black & white,
1) Blind embossing: The design is engraved into the camera-ready art.
plate. A male or counter die is produced by
casing or forming a thermoplastic resin into the 3) Knowledge of or an actual piece of stock to be
female die and the male and female dies are embossed. This is useful for the engraver to
mounted on opposing platens to transfer the ascertain the depths of the embossing and the
embossing under pressure (and ideally heat) to bevel or sharpness of the images embossed.
the paper or board stock
Once an embossing die has been completed,
2) Register embossing: This is the same as blind duplicate dies can be manufactured from the
embossing except that the embossing must original in bakelite, plastic or by an electroform
register to printing on the stock it is not unusual plating process which creates a layered metal die.
for people in the industry to refer to all Today embossing is prevalent on greeting
embossing as “blind embossing.” This is not cards, invitations, book covers, business cards and
only a misnomer, but can lead to problems in letterheads, annual reports, calendars, trading cards
production since register embossing must match and a multitude of other printed pieces and an
exactly to the printing. embossing capability can greatly enhance the
bottom line of a printer or trade finisher.

Note: This information provided by Cape Art Die, Inc.
DIE-MAKING: THE PROCESS OF CREATING A DIE TO

GLOSSARY EMBOSS, DEBOSS, FOILSTAMP OR DIE-CUT PAPER OR
ART, CAMERA-READY: CLEAN, HIGH-CONTRAST FILM BOARD STOCK.
OR BLACK & WHITE IMAGES THAT CAN BE
PHOTOGRAPHED FOR DIE OR PATTERN PRODUCTION. DIE SIZE: THE ACTUAL SIZE OF THE DIE OR PLATE
REGARDLESS OF THE IMAGE SIZE. FOE EXAMPLE; THE
BEVELED EDGE: THE EDGE OF AN EMBOSSED OR IMAGE SIZE COULD BE 3"X4" BUT THE DIE OR PLATE IS
DEBOSSED AREA ON A ON A DIE, ENGRAVED AT A REQUIRED TO BE 9" X 8" TO FIT IN A FIXTURE ON THE
SPECIFIC ANGLE TO THE PLANE OF THE PAPER. PLATEN. PLATE OR DIE SIZE IS MORE IMPORTANT THAN
BEVELS, LIKE DEPTHS ARE DETERMINED BY THE IMAGE SIZE WHEN ORDERING PHOTOENGRAVED DIES.
PROPERTIES OF THE PAPER STOCK.
DIE, STEEL RULE: A DIE USED FOR DIE-CUTTING.
BLIND EMBOSS: RAISING (EMBOSSING) THE IMAGE USUALLY MADE WITH 1132" RULE SET INTO WOOD OR
WITHOUT THE BENEFIT OF PRINTING OR FOIL. THE COMPOSITE MATERIAL. TYPICALLY TYPE HIGH (.918).
EMBOSSING ALONE CREATES THE DESIRED EFFECT.
DOMED: A ROUNDED SHAPE IN AN EMBOSSING OR
CHISEL: A TOOL USED WITH A HAMMER IN THE DEBOSSING DIE. EMBOSS: TO RAISE THE SURFACE OF A
PRODUCTION OF AN EMBOSSING DIE. ALSO, A "V" PAPER OR BOARD STOCK WITH A DIE
SHAPE IN THE EMBOSSING/DEBOSSING.
ENGRAVE: TO CUT A DESIGN OR LETTERING INTO A
DEBOSS: THE OPPOSITE OF EMBOSSING. THE PROCESS DIE.
OF LOWERING THE SURFACE OF THE PAPER WITH A
DIE. FOIL EMBOSSING: TO EMBOSS AND TRANSFER FOIL IN
ONE PASS BY MEANS OF A COMBINATION DIE.
DIE, COMBINATION: A FEMALE DIE USED TO EMBOSS
AND TRANSFER FOIL IN ONE PRESS PASS. FOIL: ROLL-LEAF STAMPING MATERIAL CONSISTING OF
A FILM CARRIER COATED WITH A RELEASE AGENT,
DIE, COUNTER: A MALE DIE MOLDED FROM THE COLOR OR TINT COAT OR A METALIZED COAT AND AN
FEMALE DIE. IT CAN EITHER BE PRE-CAST BY THE ADHESIVE COAT, FOR THE PURPOSE OF TRANS FERING
ENGRAVER OR CREATED ON THE PRESS AS PART OF THE COATING ONTO PAPER OR BOARD STOCK UNDER
THE MAKE-READY PROCESS. IT IS USUALLY MADE OF HEAT AND PRESSURE. FOILS CAN BE OPAQUE COLORED
PLASTIC RESIN AND IS USED TO PRESS THE PAPER INTO (PIGMENTED), GLOSS, TINT METALIC OR PATTERNED.
THE DIE. THE LATEST DEVELOPMENTS IN FOILS ARE
HOLOGRAMS AND COLD RELEASE FOILS.
DIE-CUTTING: PIERCING THE PAPER OR BOARD STOCK
WITH A DIE MADE WITH SHARPENED STEEL RULE. GLAZING: PRODUCING SHINY OR BURNISHED EFFECT
ON THE STOCK WITH HEAT AND PRESSURE.
DIE, DUPLICATE: MOLDED REPRODUCTIONS OF THE FREQUENTLY DONE WITH TEXTURED STOCK TO "IRON
ORIGINAL DIE. VERY USEFUL FOR LONG RUNS OUT' THE TEXTURE.
REQUIRING MORE THAN ONE OF THE SAME DIE.
GRAVERS: HAND TOOLS UTILIZED BY THE ENGRAVER
DIE, EMBOSSING: FEMALE DIE USED TO RAISE A IN DIE PRODUCTION.
DESIGN ON PAPER WITH HEAT AND PRESSURE. IT CAN
BE PHOTOENGRAVED, MACHINED OR HAND MODELED. GRINDER: ELECTRICAL OR AIR TURBINE POWERED
TOOL FOR ENGRAVING DIES.
DIE, FOIL-STAMPING: A DIE USED TO TRANSFER FOIL
(ROLLED LEAF) TO PAPER OR BOARD STOCK. ALSO
"FLAT-STAMP DIE".
Continued on next page

Continued from preceding page
HOT-STAMPING: TRANSFERRING FOIL TO PAPER OR REGISTER EMBOSSING (DEBOSSING): EMBOSSING OR

BOARD STOCK WITH A DIE USING HEAT AND PRESSURE. DEBOSSING THAT MUST REGISTER TO A PRINTED
IMAGE. REVERSE: AREAS IN THE DESIGN WHERE THE
IMAGE AREA: THE ACTUAL SIZE OR MEASUREMENTS PAPER SHOWS THROUGH THE STAMPING (ALSO CALLED
OF THE EMBOSSED OR STAMPED DESIGN. THE DIE OR "DROP-OUT").
PLATE USUALLY EXTENDS 1/2" BEYOND THE IMAGE
AREA ON ALL SIDES. SCORING: CREASING PAPER OR BOARD STOCK WITH A
DIE TO FACILITATE FOLDING.
MAKEREADY: THE PROCESS OF SETTING-UP A PRESS
FOR EMBOSSING, STAMPING, DIE-CUTTING, ETC. SCULPTED DIE: A HAND ENGRAVED DIE. THE PROCESS
OF MODELING THE METAL INTO SHAPES, ANGLES,
MULTI-LEVEL: EMBOSSING OR DEBOSSING A DESIGN BEVELS AND TEXTURES TO EMBOSS THREE
OR IMAGE TO MANY LEVELS WITH THE SAME DIE. DIMENSIONAL IMAGES.
NON-IMAGE AREA: THE AREA WITHIN A DESIGN THAT SINGLE-LEVEL: THE PROCESS OF EMBOSSING OR
DOES NOT STAMP OR EMBOSS. DEBOSSING AN IMAGE TO ONLY ONE LEVEL. THIS TYPE
OF DIE IS USED FREQUENTLY FOR LETTERING OR
PANTOGRAPH: MACHINE FOR ENGRAVING A DIE BY PANELS.
MEANS OF TRACING A TEMPLATE OR PATTERN TO
REPRODUCE A DESIGN INTO THE METAL. STEP AND REPEAT: PRODUCING AN IDENTICAL IMAGE
MORE THAN ONCE ON A SINGLE DIE. THE IMAGES ARE
PAPER LEVEL: THE REFERENCE POINT FOR ALL EXACTLY THE SAME DISTANCE FROM EACH OTHER
EMBOSSING OR DEBOSSING. EMBOSSING RAISES THE WHEN MEASURED FROM A GIVEN POINT ON ONE IMAGE
DESIGN ABOVE THE PAPER LEVEL, DEBOSSING LOWERS TO THE SAME POINT ON THE NEXT. THIS DISTANCE IS
THE DESIGN BELOW PAPER LEVEL.. REFERRED TO AS A CENTER. THIS METHOD IS USED TO
PRODUCE MULTIPLE-UP DIES.
PHOTOENGRAVING: A PROCESS FOR ENGRAVING A DIE
BY MEANS OF PHOTOGRAPHING AN IMAGE ON THE TEMPLATE: A PATTERN USED FOR TRACING ON A
METAL WITH AN ACID RESISTANCE EMULSION THEN PANTOGRAPH MACHINE. THE TEMPLATE IS LARGER
EXPOSING THE DIE TO ACID TO ETCH METAL AWAY. THAN THE FINISHED IMAGE USUALLY AT A RATIO OF
FOR AN EMBOSSING DIE THE IMAGE AREA IS ETCHED. 2/1 OR GREATER.
FOR A STAMPING DIE THE BACKGROUND IS ETCHED.
PIN-REGISTER: A SYSTEM FOR PRE-REGISTERING THE TRACING: AN EXACT REPRODUCTION OF A DESIGN BY
DIE AND COUNTER WITH PINS INSERTED THROUGH SCRATCHING INTO CLEAR ACETATE WITH A SHARP
HOLES DRILLED IN EACH. THE DIE AND COUNTER ARE POINTED STYLUS, OR USING A VERY THIN LEAD PENCIL
MOUNTED ON THE PRESS AND THE PINS REMOVED ON FROSTED ACETATE. USED TO TRANSFER AN IMAGE
BEFORE RUNNING THE PIECE. ONTO THE PLATE FOR ENGRAVING.
PROOF: AN IMPRESSION OF THE DIE EITHER AFTER

COMPLETION OR WHILE THE ENGRAVING PROCESS IS
ONGOING TO SHOW THE EFFECTS OF THE EMBOSSING,
DIE-CUTTING, ETC.

for
Embossing
Diecutting and Embossing Guidelines
1. Know your tonnage requirement:

One ton per square inch for embossing
300 pounds per linear inch for diecutting
80 pounds per linear inch for creasing
25 pounds per linear inch for rubber
2. All embossing must be 1/4"/6mm to 3/8"/9.5mm from

scores and cuts.
3. For .937"/23.8mm knife, embossing die set thickness plus

lumber thickness must not exceed .937"/23.8mm.
4. Counter dies are usually .040"/1mm thick.
5. Makeready die cutting first. When cutting properly, set the

counter dies and work on the embossing impression.
Lumber or Die (Female) Counter Base Male/Female TOTAL

Aluminum Block Thickness Thickness Sandwich
.625"/15.9mm .235"/6mm .040"/1mm .275"/7mm .900"/22.9mm *
.750"/19mm .110"/2.8mm .040"/1mm .150"/3.8mm .900"/22.9mm *
.687"/17.5mm .170"/4.3mm .040"/1mm .210"/5.3mm .897"/22.8mm *
.562"/14mm .295"/7.5mm .040"/1mm .335"/8.5mm .897"/22.8 *
* Based on .937"/23.8mm cutting rule and allowing .010"/.25mm for adjustment.
The Tolerances for the “Embossing Sandwich” is as follows:

Female thickness +/- .005"/.127mm
Male Thickness +/- .002"/.051mm
“Sandwich” (Combination of Male and Female Dies) +/- .003"/.076mm

13-2A
Stamping and Embossing Dies
Note: This article reprinted from IADD’s The Cutting Edge, December 2001
Written by Ralph H. Pope, Boston, MA, USA.
While gearing up for this latest literary The die can take many shapes and be made of
adventure, it seemed appropriate to look up the many different materials but in this article we will
subject matter in my nice new Dictionary of discuss only the types most commonly used in
Graphic Arts Terms. Unfortunately, the best it today’s finishing industry.
could do follows:
Acid etch. The least labor-intensive way of die
Stamping dies: Deeply routed metal plates used making is to etch the die material with acid. Before
in heavy-duty box printing. doing an acid etch, we use a photographic process
to chemically mask the areas of die we don’t want
Somehow this just didn’t seem an adequate or to remove, then we expose the area we want
complete description of those thingamabobs we put removed to an acid spray, and the unwanted
on our presses to perpetrate the various types of material is etched away.
paper manipulation we refer to generically as
stamping and embossing. So, I’ll try in this article Nitric acid is used with magnesium, and ferric
to give some definition to diemaking methods, die chloride is used to etch brass and copper.
uses and die materials.
Routing. A second method of removing material
Having a more detailed knowledge of stamping is to rout away the unwanted areas mechanically
die construction will be helpful to you, whether for with a milling machine. This process is best for
the purpose of making intelligent purchases of removing additional material from dies that have
stamping dies to be run in-house, to promote more been acid etched but still need further trimming and
enlightened buying of stamping services from your for creating dies with a geometric pattern and not
friendly, trusted finisher (an oxymoron?) or just for much fine detail. Using a milling machine to create
your general enlightenment. So here goes. a finished die with curves and detail requires skill
and training.
Stamping/embossing press. A letterpress style
press where the die replaces the type, foil replaces Hand engraving. The third method of removing
the ink and the bed of the press is heated. metal is referred to as hand engraving or modeling.
In making a modeled die, the engraver works with
Since stamping is essentially a letterpress hand tools and small power tools to remove material
operation, the die (replacing letterpress type) needs and to create a sculpture in reverse. This is the most
a raised mirror image of what we want to print, or time consuming and therefore the most expensive of
in the case of an emboss, we need a depressed the methods of manufacturing stamping/embossing
mirror image of the pattern we wish to raise. In any dies.
case, our die is created by removing some material
and leaving some behind—so our three primary Now that we’ve got the basics of how dies are
methods of die manufacturing are three methods of made, let’s move on to the three types of dies and
removing material. what we do with them.

3 endorsement by the IADD.
This listing does not constitute
Flat stamping. Flat stamping transfers foil to the embossed portion of the die while a sheet of foil is
surface of a sheet of paper without raising or drawn across the face of the die. The thin edge
depressing the surface of the paper. A flat foil surrounding the combination stamping area creates the
stamping die is usually made from a 1/4" thick sheet boundary between the stamped/embossed area and the
of metal and is routed or acid etched to leave raised a non-stamped area. The paper is pushed up into the
mirror image of the pattern to be stamped. The cavity, raising the image, and foil is applied in a
routing is done with a milling machine. These dies are single pass through the press.
typically made using magnesium, brass or copper.
Magnesium, the least expensive and softest of the As mentioned earlier, the most common materials
materials, is the easiest to etch and is usually acid used to craft the three basic types of dies are
etched, not routed. Brass can be etched, but the magnesium, copper and brass.
process is more difficult and time consuming than Magnesium. Magnesium has two very strong
etching copper or magnesium. As a result, many brass advantages. First, the material is less expensive than
flat stamping dies are mechanically routed. Copper brass or copper and second, it is soft and easy to
etches well, so copper flat stamping dies are usually work. Mag is easily etched with acid and is a good
created with an acid etch. material for flat stamping dies. A mag flat stamping
Embossing. Embossing creates an image by die is good for press runs of up to 15,000
raising a portion of a paper sheet. Our embossing die impressions. Since it is fairly soft and malleable, it is
starts life as the same 1/4" thick piece of metal as the easy to work by hand and is a good material for a
flat stamping die. Instead of removing everything that modeled embossing die. Since these mag embossing
will not appear in the final image, we remove material dies last fairly well, we would recommend this
and leave a void to shape the paper. Think of an material for run-lengths of up to 30,000. The softness
embossing die as sculpture in reverse. In a simple of the material, on the other hand, prevents it from
geometric emboss with discrete levels, the embossing being the choice for combination stamping dies. The
die can be produced fairly inexpensively with an acid thin edge that separates the emboss stamp area from
etch process. However if we want to show a raised the “dead” area in a combo die is just too susceptible
image where different levels flow smoothly into each to damage. A word of warning: the small
other, the die will be made largely by hand as a imperfections that are occasionally found in recycled
“modeled” die—the diemaker working as a sculptor paper can raise havoc with mag stamping dies. We
in reverse, removing material from the cavity that will recommend that you ask your finisher to use the
form the paper into the desired shape. harder brass or copper dies when stamping recycled
papers.
Combination stamping. In this process, foil is
transferred to the surface of the paper as in flat Copper. Copper is frequently used for longer-run
stamping at the same time the surface of the paper is flat stamping dies. Although the material is more
raised as in embossing—i.e., a little of both of the expensive than mag, it can still be acid etched,
above. In flat stamping, we removed everything helping to keep the cost down. Since copper is
except the mirror image of the pattern we wished to difficult to hand engrave, we use brass when we need
stamp, and in the embossing die we removed the a hard die for combination stamping or embossing in
image itself leaving a cavity with the reverse of the a sculpted pattern.
image we wished to emboss. Not surprisingly, in Brass. Brass provides both long life and good
combination stamping we remove all of the modeling characteristics, but it isn’t great for flat
non-stamping material (as with flat stamping) and we stamping dies with a lot of detail since it’s difficult to
also remove material from the now raised area (as acid etch. Brass is the material of choice for
with the embossing die). What is left is a thin edge combination stamping dies, giving the best
separating the embossing portion of the die from the combination of workability and durability.
“dead” area. During the combination stamping
operation, the paper material is shoved into the

4 endorsement by the IADD.
This listing does not constitute
CHAPTER 14
THERMAL DIES
General Information Regarding Thermal Dies & Diecutting
There’s Nothing Like a Hot Kiss
Note: This article Written by Rudy Henn
Owosso Graphic Arts, Inc., Owosso, MI, USA
There’s Nothing Like a Hot Kiss! cornering, allowing fast and accurate weeding.
There’s just nothing like it! From fleet markings to Thermal dies can be quickly reproduced from
self-adhesive alphabets, from delicate pin stripings computer imaging, camera-ready artwork, Ruby
to splattered-effect decals, from kid’s stickers to Lithe, and film positives and negatives. Because
safety signage, thermal kiss-cutting offers a world photoengravings are not made using labor-intensive
of possibilities for the graphic arts industry. Also manual tooling, thermal dies can be produced with
known as face cutting, or just thermal diecutting, fast turnaround, normally same-day, and lower
this technique frees designers, screenprinters, and costs. Still, despite all the advantages of thermal
diecutters to create products with complex designs dies, for some jobs they are just inappropriate.
and intricate details unachievable with conventional Magnesium dies won’t cut through paper or other
steel-rule cutting dies. materials that contain fibers.
This chapter is intended to give you an
overview of using magnesium thermal dies for How Does Thermal Die “Cutting” Work?
cutting pressure-sensitive vinyls. There are six “Cutting” might be a misleading word. Thermal
things that I hope to do; explain why thermal die dies use a combination of three factors to melt the
use is increasing; reveal how thermal dies work; face of pressure-sensitive vinyls: pressure; dwell
cover the basics of how these dies are made; sketch time; and heat. Thermal dies just “kiss” the vinyl,
out some important considerations for designing and leaving the paper liner, or carrier, intact (see
ordering dies; outline cutting techniques; and tell Diagram 1). Of course, different combinations of
you about magnesium die maintenance and storage. heat, dwell, and pressure are necessary for crisp,
My goal is to give you some insights on achieving sharp “cutting” of the various types of vinyls. As a
the best results from your diemaker. I hope you rule of thumb, always start with lower
enjoy this chapter, and please feel free to contact temperatures, and work your way up gradually. For
me or your own supplier. 4 mil vinyl, your press temperature should be set at
275F, and then gradually increased until a clean cut
Why Thermal Dies? is achieved.
The market for thermal dies continues to grow both
because they’re easy to use, and the vinyls that
thermal dies can cut have a wide range of
applicability. New pressure-sensitive vinyls are
available for a huge range of applications: indoors,
outdoors, underwater, low-temperature, and
reflective, just to name a few. And as noted before,
vinyls can be used on an endless number of
products from decals to pin striping.
Magnesium thermal dies are chemically
photoengraved, which, just like it sounds, means
that artwork is photographically transferred onto
sheets of magnesium. The flexibility of photography
allows for the intricate detailing and uninterrupted

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Special attention has to be given when using negative, using artwork in whatever format you
layered screen inks and UV coatings. Higher supply. Please remember: better initial image
temperatures are needed for reflective and quality will yield higher-quality end products, and
screen-printed materials, ranging as high as 350F. higher customer satisfaction. Today, the best quality
Dwell times vary according to the material and heat fine-line negatives come from computer electronic
that you are running. One-half to two seconds is the imaging, which can produce consistent die lines.
norm for dwell time. Some people cut their dwell Most photoengravers offer computer-imaging
time down by using higher temperatures, with services, which allow customers to send orders via
experience being their guide. modems and E-mail.
The final factor, pressure, is greatly affected Obviously, the goal of using a thermal die is
by the configuration of your die. Intricate details to precisely cut your customer’s artwork. It’s vital
require relatively more pressure than large, open in matching this artwork to remember that heat (the
areas. Also, you may want to adjust the type of thermal part of your die) expands all metals
counter board underlay you use depending on the including magnesium. The formula in Diagram 2
image being cut. Commonly used counter board will help you, especially with critical registration.
underlays are posterboard, chipboard, and Be sure to ask your die maker whether they or you
polyurethane. Keeping these three factors in cheek will make this adjustment.
will reduce the build-up of melted vinyl on the
shoulders of your die, and give you a more
pleasurable cutting experience.
It’s an important insight that these three
factors jointly allow thermal dies to melt vinyls.
Before discussing cutting strategies, it may be
helpful to explain how a thermal die is made--the
anatomy of a hot kiss.
What’s in a Thermal Die?

Magnesium thermal dies are typically produced in
two thicknesses. The most commonly used
thickness for four-poster presses is 11 point (.154").
Then there is .250" (18 point), typically used on
clamshell presses. The size of thermal dies is only
limited by your press size; today’s photoengravers
can etch cutting images ranging from a single
square inch to ten feet long. Now 30 inches is the
maximum width, but soon 48 inch widths will be
available.
Since etched magnesium thermal dies are
produced photographically, care must be taken in
preparing the film negatives, Ruby Lithes etc. Your
diemaker has to transfer your images onto the
photosensitized magnesium by producing a fine-line

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Photoengraving demands craftsmanship. Cutting With Your Hot Kiss

After die image is developed onto highly polished Properly mounted dies on a well-maintained press
magnesium, every fine detail, every inch, must be hardly require make ready, since the surface of the
inspected for broken lines, pinholes, or missing die is of even height. An even counter board
detail. The magnesium is then etched in acid baths. underlay, such as poster board, chip hoard or
Diluted nitric acid containing solvents and water is polyurethane will help in cutting, and it will also
splashed against the image surface of the protect the edges of the die from dulling or
magnesium, etching away everything except the smashing.
desired line image. The process has to be monitored To prevent the melted vinyl from sticking
for constantly changing acid concentrations, and building up on die shoulders, use a release
temperatures, and humidity, which all fluctuate agent. Photoengravers now offer more advanced
depending on the amount of open areas of the image Teflon-like release coatings, which have better
being etched. releasing properties than older spray-ons. Release
All these factors influence the depth, coatings are most helpful on fine detail and difficult
shoulder angle and cutting-edge width of a thermal jobs. Even with the newer release agents you need
die; whether it’s a steep, sharp shoulder or sloping to keep your heat settings in check. Too much heat
and wide (see Diagram 3). The cutting edge for 2 will result in burned material, raised ridges on part
mil to 4 mil vinyl should have a surface of .002" to edges, and, in some eases, cut parts that get heat
.004", depending on the boldness of the image, or welded to their backing sheets.
if imprinted vinyl is used. The regular etching depth By now you’re probably wondering how
is between .060"and .075" for basic cutting needs. many cutting impressions are possible with
More depth can be achieved for special cutting magnesium dies. Just as for steel rule dies, the
requirements. Please note that only the first material substrate and temperature being used
.010-.012 inches will actually do the cutting of your contribute to the longevity of a die. For reflective
vinyl. The remainder of the die’s depth will help vinyl with beads, a die might only last for 300 to
prevent scorching of your substrate, keeping it away 500 strikes. Contrast this with a report I received
from the heated die. from Houston about a company getting over a
million impressions, on 2-mil vinyl-and they’re still
using that same die. I’m pretty sure this isn’t just
another Tall Tale from Texas!
Putting bearers around the die can prevent
damage from too much pressure. Dies should be
mounted as centered on the press plate as possible,
so that even pressure is applied. If a die design has
images which are lop-sided, off to one side, this
creates an unbalanced load on the press. For more
uniform cutting, place pressure bearers on the open
side to compensate.

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I recommend you talk to a knowledgeable Here are just a few more tips to remember.
person when cutting unusual printed material or Magnesium is a softer metal; it is almost impossible
heavy UV coatings. This will make you aware of to repair. A good method for storing thermal dies is
possible unexpected trouble, and it will help you get to drill a hole at one end for hanging. Hanging your
a clean, sharp cut. dies avoids warping, but you can just as effectively
stack your dies by taping a protective sheet of
Thermal Die Maintenance and Storage chipboard over the face of the die. The die will stay
When finished cutting, it is best to remove the die straight and not be damaged when stacked.
from the press while it is still hot, gently prying it Although the cutting edges are not sharp, they need
off (the hotter the die is, the easier it will come off) to be protected.
taking care not to let it fall face down. Before the
die cools, use a natural-fiber brush to scrub off any So Go Get a Hot Kiss!
residues. We recommend a tampico fiber brush, Following these general guidelines will help make
which can be found at most hardware stares. Dies kiss-cutting a joy, rather than a job. Most
are easier to clean while still at cutting temperature. photoengravers are available for trouble shooting
and free estimates. Vinyl manufacturers are also a
To avoid magnesium corrosion, use a spray, great source. Give them a call. And remember:
such as Pam™ to coat the die. Of course, this there’s nothing like a hot kiss!
prevention is not necessary if your dies are already For other die needs such as: debossing,
coated with a Teflon like release coating. Dies last embossing, foil stamping and membrane switch
longer when stored in a low-moisture, chemical-free overlay embossing, please contact your diemaker.
atmosphere, either hung or stored flat.

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CHAPTER 15
PLOTTERS
General Information Regarding Plotters,
Cutters, Scoring Machines
General Information
The plotter sample maker has become a popular tool in the design department of die
makers and converters. It is a machine that will output graphic information from a computer
generated CAD file. When operated as a plotter it will draw with either liquid ink, felt tip or ball
point pen directly on the drafting media such as paper mylar, vellum or even die board.
The system is also capable of producing a sample of the design with the material that will
be used in production. These machines come equipped with cutting and creasing (scoring) tools
which will create the sample. Sample making has been accomplished in the areas of paper,
paper board, corrugated. plastic corrugated, foamcorr, gaskets, electronic membrane material
and a host of other materials that can be cut with a knife and die. Prior to sample maker
machines the designer had to either produce a one up die or produce the sample by hand which
was time consuming and costly. These machines have allowed the user to serve more customers
faster and better.
The list of application for this equipment continues to grow as the enterprising user
becomes more familiar with the system's capability. This list includes: sample making, small lot
production, PVC samples for a proof sample, full form vinyl or mylar plots for print registration,
stripping pin check to synch up tools, spot up plots to check uniform die pressure, plots for
checking machine and tool accuracy, creating counter masks, cutting coating (varnish) blankets,
scribe coat and rubylith materials, kiss cutting of labels, cutting panel fillers and cutting foam for
blanking. These machines also have the capability of plotting directly on die board so the die may
be jigged in the traditional manner.
Several issues should be considered when selecting a plotter sample maker. First and
foremost is what machine will meet the die makers needs of serving the customer base. A variety
of models are available from the plotter sample maker manufactures that have been designed
for various applications. For example, a high accuracy machine would be more suited for a die
maker serving the high tolerance market of electronic membrane switches Vs a die maker
serving the folding carton market. A die maker serving the POP or corrugated segment will
require a larger machine than the die maker serving the folding carton segment. Many plotter
sample table manufactures will also provide machines that will accommodate a variety of tools
including drills, routers, and milling tools to name a few. Consideration should be given to what
tools will be needed and what tools are unnecessary. There is no purpose in purchasing tools that
will not be used. On the other hand, the user should make sure additional tooling can be added
to the equipment in the event that his/her requirements change over time.
All of the plotter sample table manufactures will be helpful in providing information on their
products. It would be well worth the time to observe the equipment in operation at a users facility
and to check references regarding the performance of the machine as well as the after sales
service and support.

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for
Plotters
Plotters
Application Specifications U.S. Metric Notes
Precision
Accuracy +/- 0.005" +/- 0.127 mm
Repeatability +/- 0.004" +/- 0.102 mm
Resolution 0.001" 0.025 mm
Folding Carton Table Flatness +/- 0.007" +/- 0.200 mm
& Gasket
Performance
Maximum 25"/sec. 63.5 cm/sec.
Velocity
Nominal Velocity 15"/sec. 38.1 cm/sec.
Plot Clearance
(for dieboard, etc.) .75" 19.050 mm
Precision
Accuracy +/- 0.007" +/- 0.178 mm
Repeatability +/- 0.004" +/- 0.102 mm
Resolution 0.001" 0.025 mm
Corrugated Performance
Maximum 11"/sec. 29.94 cm/sec.
Velocity
Plot Clearance
(for dieboard, etc.) .75" 19.050 mm

15-2A
CHAPTER 16
DIECUTTING
General Information Regarding Diecutting
History of the Diecutting Process in America
Note: This information adapted from an article in DDIN - International
Written by Robert A. Larson, President, Larson WorldWide, Norwell, MA, USA.
In the Beginning... The Leather and Shoe Industry

A simplistic example of diecutting is your mother The earliest cutting dies were probably used in the
making cookies in her kitchen. She would first roll shoe industry. By 1760, the first shoe factory had
out the cookie dough. Then using an inexpensive appeared in Massachusetts and shoes began to be
cookie cutter of some design like a heart, a “mass produced.” One of the developments at that
Christmas tree or a Ginger Bread Man, she would time was the use of forged mallet handle dies which
cut out by hand many duplicates of the various cut out heavy sole leather, insoles and component
shapes to make her cookies This was accomplished parts of shoes. The mallet handle die had a handle
by simply pushing the cookie cutter through the seam welded onto the back of the sharp edged
dough until the edge of the cookie cutter struck cutting die. A diecutter would hold the die in one
against the counter top or some other cutting hand by it's handle, place the die over a section of
surface. In reality, she was diecutting her cookies. leather and strike the end of the handle with a
Up until the Industrial Revolution, all sledge hammer held in his other hand. The die
products were made on an individual basis by a would go through the leather and into an end grain
craftsman of one type or another. This all changed wooden block of hard maple.
over the past two hundred years when the Industrial The clicker press introduced a new type of
Revolution created changes in the processes and cutting die. The clicker die was an open forged or
organization of production from a handicraft to bent die that was heat treated for hardness. The dies
industrial or machine manufacturing process. came in several normal heights of 9/16", 3/4" and
The development of sharp edged cutting dies 1-1/4" depending upon use. 9/16" and 3/4" dies
probably developed before the Industrial were made double edge so that a left and right side
Revolution. Sharp edged cutting dies were another could be cut from one die simply by turning over
tool that were developed to standardize component the die. In the late 1800’s and into the early 1900’s,
parts that went into many products for mass in areas where there were many shoe factories, a
production. new breed of forged clicker and high diemakers
Little if anything has been written about the started out their businesses to service the shoe
use of cutting dies in the hand craft era of industry and other leather goods companies.
producing products out of leather, fabrics or paper.
It is conceivable that some artisan or craftsman may The Graphic Arts, Paper and
have gotten the bright idea to fashion a crude Paperboard Trades
cutting die shape to cut out small pieces of leather The basic design of a flatbed press used in
or fabric. The development of the diecutting process
diecutting paper, embossing or foil stamping, was
developed in several separate industries; the originally modeled after a wooden wine press. The
printing of paper along with the production of
first letterpress for printing in America was
envelopes and labels, the development of the paper
reportedly built by Adam Ramage in 1790. He
box and in the shoe industry and associated leather
substituted an iron platen and iron bed for the
goods trades.
wooded and stone parts used originally. This was a
great advance in printing. In 1798, Charles the

Third Earl of Stanhope built the first press with a in 1900. It was a simple machine that bent the thin
one piece, cast iron frame and in 1816, George ribbon die steel. Mr. John Arthur Richards, born in
Climer of Philadelphia built the Colombian all iron Newark, Ohio in 1880 learned his trade as a
press. The Colombian press would make an pressman in the printing trades. He worked for a
impression with one pull of the handle and bore a series of printers, newspapers and printing press
platen capacity as large as 23" x 32". Its biggest manufactures to include the Meihle Printing Press
drawback was that it took 11 different press & Mfg. Company. On a trip to visit his brother in
operations and could only print one sheet of paper Fort Wayne, Indiana in 1910 he saw a man making
at a time. steel rule dies in the window of the Fort Wayne
The Gordon press was introduced in 1851 by Paper Box Company.
George Phileus Gordon, who in 1862 developed his He asked the man what he bent the rule with
improved Franklin Gordon press. This came to and the man pointed to a small machine saying that
become a standard printing press in the commercial it was the “Multiform made across the street.” Mr.
printing industry in the U.S.A. for 75 years. Richards purchased the patent, patterns and business
Robert Gair is given credit for inventing of the J. Welty Company from Mr. Welty's widow.
steel rule die cutting in America in 1879. Robert That began the Richards family’s involvement in
Gair was a printer and it is told that one day he producing machinery and equipment for producing
inadvertently inserted an over height crease rule steel rule and steel rule blanking dies. In 1912, the
into a letter press lock-up that he was constructing. J. A. Richards Company produced their first line of
He found out that instead of creasing the paper as Multiform saws for cutting the die lines in steel rule
desired, he cut the paper. He is also credited with dies. These jig saws were operated by foot power,
being the creator of the diecut and creased folding belt drive and later by motor drive.
carton. The platen printing press therefore, In the first half of the 1900’s many advances
developed a new use in diecutting. In the printing were made in the types of cutting dies produced and
industry there were three forms of letterpress the types of cutting presses developed to cut out a
machinery: the platen press, the later developed whole array of materials and products. In the
cylinder press and rotary press. These two later 1960’s and 70’s new methods of cutting soft to
types of printing presses also were adopted to semi-rigid materials were developed such as laser
become diecutting presses. cutting, waterjet cutting and computerized knife
The development of commercial steel rule blade cutting. Today, cutting dies are still the
diecutting blades was pioneered in North America mainstay and the choice of many manufacturers for
by the J. F. Helmold Company established in 1881. cutting component parts of many products.
Helmold was a pioneer in developing a multitude of In 1962 William F. Ward of The Ward
products used in the graphic arts industry, folding Machine Company developed the soft anvil rotary
cartons and corrugated containers, and later in die cutting concept using a rotary steel rule cutting
displays, gaskets and related industries. Helmold die. Up to that time, manufacturers of corrugated
pioneered the development and production of steel containers used flat steel rule dies. Mr. Ward
rule cutting, perforating, and creasing rules and wanted to build a rotary diecutting press that would
equipment to produce steel rule dies. In England, run twice as fast as a flat die cutter, could handle a
the Notting Company was also producing cutting corrugated sheet twice the size of a flat press and
rules for steel rule dies. sell his press for one half the price of a flat
The first steel rule bender to bend steel rule diecutting press. The soft anvil rotary diecutting
stock for steel rule dies, was invented by Joel Welty press opened a whole new avenue not only to

corrugated box makers to produce specialty die cut machines, lathes and other automated machine tools
boxes at lower unit cost, but also to many other were rapidly taking over manual operations. The
products in the converting industry such as felt machine shops that did invest in NC tooling centers
products, non-woven products and a host of other and NC lathes and milling machines replaced the
materials and products. old hand skills of the earlier tool and diemaker. In
Diecutting presses have been improved and the late 1970’s several more advanced clicker
new types of presses have been developed, diemakers had introduced NC milling machines into
especially the rotary die presses now commonly their operations to produce solid milled clicker dies
used for high speed diecutting of labels, envelop to close tolerances. In 1980, the Boston Cutting Die
windows and business forms. Computer controlled Company was the first clicker diemaker to install a
diecutting systems today provide converters with wire EDM machine to produce close tolerance solid
accurate, high speed cutting systems. clicker and high dies. It was now possible to
Out of the early platen printing presses produce intricate cutting die designs out of solid die
developed a whole new generation of high speed steel to tolerances as close as +/- 0.0006". Where
automatic platen presses such as Bobst Autoplaten it would have taken an experienced machinist days
press that can cut, crease, emboss, hot stamp and to create a die, the CNC controlled wire EDM
strip up to 9600 sheets of paper stock per hour. machine could wire cut the design in hours.
We have come a long way since the days of In 1968, S. Ray Miller, President of Atlas
a diecutter whacking out leather parts using a mallet Die, Company in Elkhart, Indiana, is credited with
handle die. From total manpower and muscle, we making a dynamic advancement in the art of
have developed computerized machine diecutting diemaking. He introduced the first laser into the
power. steel rule die industry for cutting the die lines in
steel rule dieboards. His first laser was controlled
Computer Age Influence on Cutting Die by a computer that required punch cards to control
the X-Y action of the table holding the dieboard.
Manufacturers
The early NC controllers with their card
In the first half of the 20th century, diemakers
processing methods was burdensome and archaic
were making steel rule dies and clicker type dies
compared to today's powerful compact computer
using the same basic techniques to produce their
systems.
cutting dies. The equipment and tooling used to
Today for a diemaker to try to produce
produce clicker dies and steel rule dies were
cutting dies without some influence of computer
essentially unchanged over a fifty to sixty year
technology would put the diemaker at a distinct
period. In the late 1950’s and early 60’s, some
competitive disadvantage. In the past ten years, the
clicker diemakers introduced hydraulic bending
computer has provided tools to the diemaker to
systems to relieve the diemaker from the strenuous
provide more accurate dies and to communicate
task of bending the heavy die steels all by hand. In
with customers with instant transfer of customers
the steel rule die business, the same basic
pattern and design files. Computer technology can
equipment, benders, bridgers, notchers and cutters
be said to have had the greatest influence in
were used for many generations. Today it is not
improving the cutting, diemaking process since its
uncommon to see steel rule diemaking equipment in
first developments in the late 1800’s. Today, cutting
a shop that is forty to fifty years old and still in use.
die manufacturing is still primarily a skilled
handmade operation, but with the use of computer
In the late 1960’s and early 70’s, especially
aided equipment, diemakers can produce a die far
in the machine shop environments, CNC milling

more accurately and economically. Third and forth stroke.

generation CAD/CAM design programs have Toggle head die cutting presses were
revolutionized the diemaking process. The rapid introduced and this type of mechanical action is
spread of the fax machine into practically every today prominent in many auto platen presses in die
company has speeded up information transferral. cutting folding cartons and paperboard. The
Today it is possible to instantly transmit pattern hydraulic controlled action cutting press superseded
designs over a fax and then reproduce the exact the mechanical action press in the 1950’s with the
dimensions by scanning the pattern designs and introduction of the USA Hytronic Model HMC-A
outputting the exact pattern on a plotter. Computer clicker press in 1958. In the 1960's USM
modem lines allow direct transmission of Corporation introduced their hydraulic controlled
information from a customer to the diemaker. receding head and traveling head cutting presses.
Improvements in flat diecutting presses,
Refinements of Manufacturing have been more a variation on a theme, rather than
Equipment in the 1980’s dynamic new developments in die cutting press
technology. The incorporation of computer controls
More accurate rule benders were produced. More
in the late 1970’s enabled diecutting presses to
attention was paid to creating tooling to produce
operate more efficiently and improve material
more accurate dies. The first semi-automatic tooling
utilization.
was introduced. The laser dieboard burning systems
Besides John Ward's development of the
were improved and with advances in computer
first rotary diecutting press system in 1962, a whole
technology and software development, the systems
new segment of the diecutting process developed in
became more reliable and user friendly. The
the narrow web printing process. Now with in-line
dieboard kerf burning speeds increased as more
printing, diecutting and stripping, many items like
powerful laser systems were introduced. In the 70’s
labels could be printed and diecut very fast and
and 80’s the laser capacity was limited to the 400 to
economically over previous flat die techniques.
500 watt range. In the early 90’s the wattage of
laser dieboard burning systems has increased to
1200, 1500 and 2000 watts of power.
Development of Diecutting Systems

First was the mechanical platen press that utilized a
flywheel mechanism to power the down stroke of
the head of the press. Once the clutch was released,
the press would cycle through one down and up

Diecuttable Materials and Products
Note: Adapted from The Case of the Cookie Cutter Part 2: Diecuttable Materials and Products,
DDIN - North America Written by Robert A. Larson, President, Larson Associates
Diecutting is suitable for all soft to semi-rigid materials. Diecutting is not practical in cutting out rigid
materials such as metals, tempered plywood, rigid ABS plastics or glass.
It is our intent to try to provide as complete a list of products and materials that are diecuttable. No list is ever
complete...there are many other possibilities.
Materials and products that can be diecut. Arranged by the United States
Standard Industrial Classification (S.I.C.) Code.
2121 Cigar wrappers Shirt bodies Hats, full brimmed
Shirt collars Uniform hats
22 - TEXTILE MILL PRODUCTS Shirt pockets 2371 Fur goods
2211 Broadwoven Fabrics, cotton Shirt undercollars Clothing
Camouflage nets Shirt yokes Fur finishing and linings
2273 Carpets and Rugs Sweatshirts Glove linings
Aircraft floor coverings 2323 Neckwear Hats, fur
Art squares Ascots Jackets, fur
Automobile floor coverings Bow ties 2381 Gloves
Bath mats and sets Neckties Glove linings
Door mats 2325 Trousers and slacks Leather gloves
Mats and matings Crotch pieces 2385 Waterproof outerwear
Scatter rugs Pockets Aprons, waterproof
2291 Felt goods Pocket flaps Bibs
2295 Coated fabrics Waistbands Clothing, waterproof
2297 Non-woven fabrics 2328 Work clothes Plastic gowns
2299 Textile goods Aprons Raincoats
Felt goods Jackets 2386 Leather and sheep lined clothing
Linings Laboratory coats Caps, leather
Padding Uniforms Clothing, leather
Pads, Fiber 2329 Clothing Coats, leather
Polishing felts Athletic clothing Hats, leather
Punched felts Field jackets, military Jackets, leather
Uniforms Vests, leather
23 - APPAREL AND OTHER TEXTILE 2339 Outerwear 2387 Apparel belts
PRODUCTS Aprons 2389 Apparel and accessories
2311 Suit & coat mfgrs. Athletic uniforms Arm bands
Coats, tailored Collar and cuff sets Band uniforms
Firefighters uniforms Dickies Burial Garments
Formal jackets Hunting coats and vests Costumes
Military Uniforms 2342 Brassiere and girdles Gowns, hospitals
Overcoats Brassieres Uniforms
Police uniforms Corsets Vestments
Suits, tailored Foundation garments 2392 House furnishings
Topcoats Girdles Bath mats
Tuxedos 2352 Hat and caps Boat cushions
Vests Baseball type caps Chair covers
2321 Shirts and night wear

Cushions Letters, plywood Die cut paper and paperboard

Ironing board pads Life preservers, cork Egg cartons
Mops, floor Novelties, wood fiber Egg cases and flats
Pads and padding Tile, cork Filing folders
Shoe bags Toothpicks, wooden Index cards and other cut cards
Slipcovers, Table mats Trays, wood Jacquard cards
Wardrobe bags Jewelers cards
2393 Textile Bags 25 - FURNITURE Lace, paper
Bags and containers 2512 Wood household furniture - Letters, cardboard
Knapsacks upholstered Library cards, paperboard
2395 Pleating, Decorative & novelty stitching Chairs, upholstered Liners for freight car doors, reinforced
Emblems, embroidered Couches, upholstered Manila folders
Quilted fabrics Furniture, upholstered Milk filter discs
2396 Automotive trimmings, apparel findings Juvenile furniture, upholstered Newsboard, pasted
Collar linings, men's coats 2514 Metal household furniture Paperboard, pasted, lined, laminated or
Findings, suits and coats Wood backs for furniture & chairs surface coated
Lapels and pockets Furniture, upholstered on metal frames Photograph folders, mats and mounts
Interlinings Seats for metal household furniture Stencil board
Pockets Tabulating cards
Linings, handbags and pocketbooks 26 - PAPER AND ALLIED PRODUCTS Waterproof cardboard
Linings, luggage 2652 Setup paperboard boxes 2677 Envelopes, printed or unprinted
Necktie linings Boxes, newsboard 2678 Stationary, tablets & related products
Shoulder pads for suits and coats Boxes, filing Correspondence type tablets
Trimmings, fabric, automotive, furniture 2653 Corrugated & solid fiber boxes Newsprint tablets and pads
Visors, caps Containers, corrugated 2679 Converted paper and paperboard
Waistbands, trousers Point of purchase items, corrugated products
2399 Fabricated textile products Hampers, corrugated Fuel cell forms, cardboard
Aprons, vest (harness) Pallets, corrugated Hats, paper
Badges, made from fabrics Partitions, corrugated Honeycomb core and board
Bandoleers Trays, corrugated Egg cartons, molded pulp
Banners, fabric 2655 Fiber can, tube, drum etc.. False faces, paper mache
Belting Containers, vulcanized & phenolic fiber Filter paper
Belts, money Malian cases Masks, paper mache
Covers, automobile tire and seats 2673 Plastics, foil & coated paper bags Pallet spacers, paper
Emblems Merchandise bags Plates, pressed and molded pulp
Flags, stars Trash bags Pressed products from wood pulp
Insignia 2657 Folding paperboard boxes Tags and labels
Pendants Folding cartons
Saddle cloths Frozen food containers 27 - PRINTING AND PUBLISHING
Ice cream containers 2752 Commercial Printing, lithographic
24 - LUMBER AND WOOD PRODUCTS Pails, paperboard Business forms
2435 Veneer & plywood, soft & hardwood Paperboard backs for blister and skin Calendars
Puzzles packaging Cards, litho
Christmas decorations 2672 Coated and Laminated Paper Color cards, paint
Toys Pressure sensitive paper and tape Labels
2493 Reconstitute wood products 2675 Die cut paper, paperboard and Menus
Flakeboard cardboard Playing cards
Hardboard Board, chip: pasted Seal, litho
Insulation board Bottlecaps and tops Souvenir cards, litho
Particle board Card cutting Tags, litho
Wafer board Cardboard foundations and cutouts 2754 Commercial printing, gravure
2499 Wood products Cardboard panels and cutouts Business forms
Boards, clip Cardboard; pasted, laminated, lined and Calendars
Carpets, cork surface coated Cards
Cork products Cards, cut and designed, unprinted Menus
Inlays, veneer Cards, tabulating and time recording Playing cards
Insulating materials, cork Cutouts, paper and cardboard seals

Tickets Insulation and cushioning Binocular cases

2759 Commercial Printing, general Shipping pads Camera cases
Business forms 3089 Plastic Products Luggage, all types
Calendars Blister packaging Sample cases
Cards Corrugated panels and boxes Satchels
Embossing on paper Flat panels Shoe Kits
Menus Floor coverings, squares and sheets Travel bags
Plating cards Gloves and mittens Valises
Tags Heels, boots and shoes Wardrobe bags
Tickets Hospital Wear 3171 Women's handbags and purses
2761 Manifold business forms Lenses 3172 Personal leather goods
Business forms, manifold Life Jackets Billfolds
Continuous forms Shutters Card cases
Tabulating card sets Siding Checkbook covers
2771 Greeting Cards Soles, boots and shoes Cigar cases
2782 Blankbook, loose-leaf binders Sponges Coin purses
Binders, loose-leaf Suitcase shells Comb cases
Ledger sheets Trays Eyeglass cases
Sample books Washers Handbags, men's
Scrap books Work Gloves Pocketbooks, men's
2789 Bookbinding and related work Sewing cases
Swatches 31 - LEATHER AND LEATHER Tobacco pouches
Diecut samples PRODUCTS Toilet kits
3111 Leather tanning and furnishings Vanity cases
30 - RUBBER AND MISC. PLASTIC Diecuttings of leather Watch straps
PRODUCTS Embossing of leather 3199 Leather goods, general
3053 Gaskets, packings and sealing devices 3131 Boot & shoe cut stock & findings Aprons, leather
Gaskets Box toes Bags, horse feeding
Grease retainers Counters Belts, safety
Oil seals Findings, boots and shoes Belts, weigh lifters
Packings Heel caps, Boots, horses
Washers Heel lifts Collars and collar pads for horses
3069 Rubber products Heels, boots and shoes Crops, riding
Apron, vulcanized rubber or rubberized Inner soles Desk sets
fabric Linings, boots and shoes Dog furnishings, collars
Bibs, vulcanized rubber or rubberized fabric Quarters, boots and shoes Halters, harness
Clothing, vulcanized rubber or rubberized Shoe soles Handles, leather luggage
fabric Tongues Helmets, leather
Diaphragms, rubber Top lifts Holsters, leather
Dress shields Uppers Jackets, welders
Flooring, rubber, tile or sheet Vamps Novelties
Heels, boots or shoes 3143 Footwear Saddles and parts
Kneeling pads, rubber Athletic shoes Spats
Life Jackets Ballet slippers Welders sleeves
Linings Boot, casual and dress
Mats and matting, bath, door Casual shoes 32 - STONE, CLAY AND GLASS
Rubber heels, soles and soling strips Moccasins PRODUCTS
Sponge rubber and sponge Orthopedics 3291 Abrasive products
rubber products Sandals Abrasive cloth, paper
Stair treads 3151 Leather gloves Abrasive coated products
Top lifts, shoes Dress and semi-dress gloves Polishing wheels
Toys, rubber Work Gloves Scouring pads
Trays, rubber Mittens Sandpaper
Wet suits, rubber Welders gloves 3292 Asbestos products
3086 Plastic foam products Golf gloves Blankets, insulation
Cushions, plastic foam 3161 Luggage Asbestos cloth
Foamed plastic products Attaché cases Woven felt asbestos

Insulating molded asbestos 3842 Orthopedic, prosthetic and surgical Balls, baseballs, softballs, footballs
Table pads and padding appliances, abdominal supporters, braces and Basketballs
3296 Mineral wool trusses Cartridge belts
Acoustical board and tiles Braces, orthopedic Cases, guns & rods
Fiberglass insulation Bulletproof vests Gloves, athletic & sports masks
Glass wool Clothing, fire resistant and protective Pads, athletics
Insulation, rockwool, saig and silica Linemen safety belts Skates, ice & roller
3299 Nonmetallic Mineral products Orthopedic devices 3953 Marking devices
Mica products Personal safety equipment Hand stamps and stencils
Prosthetic appliances Letters
36 - ELECTRONIC & OTHER Space suits Paper stencils
ELECTRONIC EQUIPMENT Suits, fire fighting, asbestos 3965 Fasteners, buttons,
3613 Switchgear & switchboard apparatus Supports, abdominal, ankle, arch & kneecap Cloth covers for buttons
Nameplates 3993 Signs and advertising specialties
Overlays and labels 39 - MISCELLANEOUS PRODUCTS Advertising displays
3622 Controls 3942 Dolls Cutouts and displays
3629 Electrical industrial equipment Clothing Lettering for signs
3644 Non-current wiring devices - Insulators Stuffed toys Signs
3672 Printed circuit boards 3944 Games & toys 3999 Misc. products
Printed circuits Craft and hobby kits and sets Artificial flowers
Flexible printed circuits Electronic toys Identification plates
Flexible switches Models airplane kits Identification tags
Puzzles Lamp shades
38 - INSTRUMENTS AND RELATED 3949 Sporting & athletic goods Ammunition
EQUIPMENT belts
The list goes on and on and one can easily see the wide array of products and materials that are being
diecut to make component parts of products of all types.
In North America, the DDIN database has discovered over 27,000 converters who diecut one or more of
the above products. They are all using some type of cutting dies and some type of cutting press.
Many converters have found a niche in the manufacturing segment converting exotic or just plain simple to
cut materials. Through trial and error, they happened upon a successful way to cut or trim component parts
for their products.

“Diecutting Tips” from Preco
Note: This information published in several issues of DDIN - North American
Provided by Preco Industries, Lenexa, Kansas USA
QUESTION: Is it possible to run very thin materials (.005 parts per minute. How a job is programmed for processing
mylar) in a hard tooled compound die at a fast speed and can be of critical importance also. We had two customers
still get the part out of the die area before the next hit? each cutting a 3" x 8" rectangular part from similar raw
With a steel rule tool, the die can be nicked and the nick materials both in coil form.
will carry the part out but this is not possible with a hard One customer slits the material to a 7" width , then
tool. sheared the coil into a 2 - out blank size. He then hand
loaded the blank into a clam shell press and got 1000 cycles
ANSWER: This is not an uncommon problem in cutting per hour. The operation sheet called for a run of 96,000
mylar spacers for membrane switches where the holes have parts so this meant about 48 hours of die cutting time.
to be very accurate so hard tools are the only way to go. The other customer slit the material into a 10" web
The best solution is to run two or perhaps more layers of and ran it in a Preco with a three out die. He was knocking
materials at a time. The web thickness doubles from .005" the part out of the web automatically and stacking in three
to .010" and becomes a more reliable transport system for stacks of 200 each. He was running 14,000 parts per hour.
the part out of the die area. The memory of the coiled Had the first customer approached the job as the
material can also be a factor, and it sometimes helps to run second customer did, he would have saved a blanking
the web with curl up instead of down. operation and cut his die cutting time from 1.2 weeks to 7
One of the pleasant benefits of such a technique is hours!
that you double production rates. One accessory that helps,
is a double unwind stand with both coils driven off separate QUESTION: How can you position preprinted material
dancer arms. Another accessory that may help if the accurately to the die, or position a die cut part downstream
bottom layer tends to slip against the idler roll in the roll accurately for a secondary operation?
feeds, is a roll feed with both top and bottom being
urethane coated, and both driven. ANSWER: For most gaskets type materials, this is not a
Feeding more than one layer at a time may be one particular requirements as the primary concern is
of the most unexplored techniques in the industry. We have minimizing the scrap web between parts. Our normal feed
some customers especially in the paper business who resolution of .010" and accuracy of +/- .005 are more than
typically run up to six layers at a time and very adequate.
successfully. On the other hand, if a progressive die is used and
the material is flimsy and won’t pilot, then a high
QUESTION: How can you better estimate the labor factor resolution feed system of .001" may be required. On
going into a particular job? occasion, we have found that using 70 durometer urethane
on the roll feeds instead of a 35 will increase the accuracy
ANSWER: You should develop a speed or cycle chart for of the feeds particularly with pre-printed materials.
your press similar to the attached sample showing strokes Probably, the most important development for
per minute versus size of part (feed progression), pressure controlling feed accuracy, however, has been photoelectric
required to cut re-registration. Using a fiber optic tip at the edge of the
the part and stroke length depending on the thickness of the part to be cut we can control feed accuracy to +/- .003"
material. Other factors to plug in for “Kentucky windage” measured from an irregular spaced mark. This capability
are the raw material form - coil or strips - and the ability has opened up the market for cutting all sorts of pre-printed
of the cut part to stay in the web (with or without nicking) materials such as nameplates from aluminum, plastic, or
at fast feed speeds. flexible stocks to point of purchase danglers to now
The example circled on the attached speed chart stamping hard or flexible circuit boards and web fed EKG
shows at 4" part cutting at 5 tons with a 1/4" stroke at 140 patches for the pharmaceutical industry.

We are just completing an interesting press for an rule on the inside for a kiss cut.
automotive manufacturer where they want to die cut a web The parts come out with really straight sides and,
of material and then position that material very accurately on inspecting the part, we found that the .932" rule cut
40" away for a secondary operation. We suggested we use through 3" or so but not the rest. Our conclusion was that
a high resolution feed system with .001" resolution and the material had compressed from 4" to about .020" before
then as a safety put a hole in the web at the time the part is it started to cut and that accounted for the straight cut and
die cut and use a photoelectric cell to be sure the part was why the .005" difference in rule height didn’t cut through
where they wanted it to be. That same technique has the last inch of foam. The stiffness of the die rubber
application for other materials such as pharmaceutical obviously was a factor in the result.
products where more than one operation is required to
make a part. QUESTION: How can you easily decurl material,
especially at the small end of a coil when the material has
QUESTION: If you have to cut a part with very tight a pronounced memory?
tolerance on a hole pattern but fairly loose tolerances on
the part outline or inner cutouts, is there a way to cut down ANSWER: One simple way is to bring the material off an
die cost rather than going to the expense of a high cost unwind stand and through a bar mounted on the underside
class A tool? of the inbound feed tray. This will put the material through
an “S” of double reverse curve and oftentimes is sufficient
ANSWER: Yes. This is a standard requirement for cutting to make the material lie reasonably flat at least long enough
flexible printed circuit boards where the holes have to be to process it through the die cutting and knockout area. In
precise and very clean (without slivers) to prevent shorting one instance where a customer was working with 2,000 lb.
the board. We also see the requirement on certain gasket coils of 22" wide chipboard stock, we built a powered
materials. decurler mounted just prior to the first roll feed on a Model
One way to cut die costs in half, if not more, is to 2430, that permitted the operator of the knockout and
use “combination tooling” where the holes are punched stacking station to electrically, and from a remote distance,
with male-female punches and the outline work is done adjust the amount of decurl being applied, depending on
with steel rule tooling. The key to doing this successfully how the material reacted in the knockout area.
is plate mounted tooling doweled into a master die set and
then controlling the position of the rule to the material and QUESTION: What are some of the knockout techniques
cutting plate very precisely as you can with a micrometer die cutters are using?
stop.
One of the problems in getting this type tool is that ANSWER: The knockout technique used varies, of course,
class A hard tool makers don’t usually know how to use with the job and all the variables that go into it such as type
steel rule, and steel rule die makers sometimes don’t have of material, size of part, cleanness of cut, length of run,
the capability to marry the two concepts. This is an repetition cycle of job order and others. The following
educational problem but there are some die makers around though are techniques that should be considered on any
the country who know how to make combination tools. job, some of which might make the knockout problem
A drawing of a combination tool and a drawing of more simple:
the plate mounted tooling system are available from Preco
Industries. A. Vacuum pick up for small light parts particularly
where static is a factor.
QUESTION: How do you cut 1" to 4" thick foam material
and get straight sides on the cut? B. Air blast.
C. Solid knockout using plug in shape of part normally cut
ANSWER: This is one we fell into by accident and come from K.O. board. Die board with flat edge rule mounted
up with a mind boggling result. One of our customers sent to 2 K.O. cylinders. Rule can be bent inward at the ends
in some 4" foam so we assumed you had to cut it with a and mounted so there is a force fit into the K.O. hole.
high rule die. We didn’t have one around so we used a
fully rubbered (stiff rubber) .937" die that had some .932" E. 1" Foam on 12" x 6" plywood mounted to two K.O.

cylinders. When the foam comes down on the cut then add the basic press set up numbers of stroke, pressure,
material, it will deform into the K.O. hole while tending feed speed and progression. Everything a set up person
to grip the web to the K.O. board. The rectangular foam needs is right there.
pad becomes a “universal” K.O. plug due to its ability to We were recently asked by a customer with really
take the shape of any configuration of K.O. hole. short runs to develop a way to get a die into the press faster -
particularly top mounted dies. The solution was to put a thin
F. Spring fingers can be used to “flip” parts out of web. plate on back of the die and do whatever patching was
Often this is useful for scatter packing and where the required in back of that plate. The die and plate would be
machine does not have to stop for offending a stack of screwed together permanently so with the patching already
papers. in place the cutting plate would not have to be changed from
die to die. We rigged up some channels mounted to the die
G. Put a loop in the material (up or down - depending on backup plate for the die and plate to slide into with snap
how the part fits into the web) with the loop between the latches at the ends so the overall die changeover time was
second and third roll feeds. As the part starts to make the reduced.
sharpest bend in the loop, oftentimes it will pop out of
the web or may require some assistance via an air blast, QUESTION: If you have die cut a web of material,
mechanical tap, etc. particularly pressure sensitive, what is the best way to
sheet it if that is what the customer requires?
H. Some parts which are extremely difficult to de-slug or
knockout can be cut and, if in strip form, put into piles ANSWER: It depends to some degree, of course, on the
where the parts can be picked out 25 or so at a time by accuracy and tolerance required on the sheet. We
hand or in a simple jig fixture. developed a sheeting knife system for a customer who die
cut pressure sensitive label stock - a pattern of rectangular
If all the above fail, do it the usual way! parts on a 8-1/2" x 11" sheet, for example - which was
then sold to the printing industry. He used steel rule dies
QUESTION: Do you know of a technique that will enable for short run orders rather than rotary dies to save die costs
the use of feed through punches with pressure sensitive and have a faster delivery time.
material that has an unusually aggressive glue? Our sheeting knife was capable of maintaining a
parallelism of edge to edge of + 1/64" and was adjustable
ANSWER: Yes. The best we have seen is to drill out the to cut in 7" to 12" widths which is what the printers
cutting plate back up plate and make a hole somewhat wanted. We also put a counter on it to permit a cut every
smaller than the punch I.D. Blast air thru this system timed 1 to 99 strokes of the press should there be a requirement
when the die is down into the material. The air will blast the for that in a cut to length line of material which had several
slug through the punch and you can get a clean part. One die cutting impressions on it.
way to time the air blast is to mount micro switch off the
stroke limit switch rod extending down from the guide pin in QUESTION: I would like to die cut centers more
the die set, or mount the switch to the top platen of the die efficiently rather than hand loading into a clicker type
set. press. How can this be done?
QUESTION: Are there any techniques for steel rule dies ANSWER: Feeding and die cutting centers can be done on
which simplify die change - over time and make it faster? an automatic feed press fairly simply by using a transfer of
carrier belt in either a continuous loop or reel to reel.
ANSWER: There are a few tricks of the trade which we
Reel to reel applications:
really like. One involves die storage. Several of our
A coil of suitable material is fed upon demand from a coil
customers use a cardboard box to store the die, the .030"
feed stand and driven through the press by the feed rollers.
cutting plate with make-ready attached, any knockout
This carrier material, if fed through the diecutting area
fixtures and then on the outside of the box, they draw an
carrying the centers, and recoiled with the unused side out
outline of the part, the customer’s name, the part number and
on a coil wind stand. After running the entire length of the

coil, it can be moved back to the feed stand and used again nice plus if your equipment is so equipped.
by cutting against the unmarked side. Like the continuous
belt, the carrier material coming off the reel acts as the
cutting surface for the diecutting operation. By using an
inexpensive carrier material, a roll could be used on each QUESTION: What are some of the knockout techniques
side and discarded, as changing of rolls requires a die cutters are using?
minimum amount of time.
ANSWER: The knockout technique used varies, of course,
Hardness of carrier material: with the job and all the variables that go into it such as type
The hardness of the carrier material may become critical in of material, size of part, cleanness of cut, length of run,
some applications. The carrier material should be harder repetition cycle of job order and others. The following
than the material being cut because the carrier material though are techniques that should be considered on any
itself serves as the cutting surface. A mechanical stop is job, some of which might make the knockout problem
used to limit the cutting depth, therefore it is imperative more simple:
that the carrier material does not compress beyond the
cutting depth, as this will not allow the rule to cut as a. Vacuum pick up for small light parts particularly where
desired. A carrier material of .015" tag paper serves as a static is a factor.
good cutting surface on softer gasket materials such as b. Air blast.
rubber, cork, etc., but has a tendency to compress
excessively under the rule edge when cutting harder c. Solid knockout using plug in shape of part normally cut
materials such as compressed asbestos. The harder gasket from K.O. board.
materials may require a belt of mylar of laminated vinyl.
d. Die board with flat edge rule mounted to 2 K.O.
Reusability of carrier material: cylinders. Rule can be bent inward at ends and mounted
Depending on the type of gasket material being cut, it may so there is a force fit into the K.O. hole the more
not be possible to cut against a carrier material which has penetration into the K.O. hole.
previously been used. This is especially true of very soft e. 1" Foam on 12" X 6" plywood mounted to two K.O.
and compressible gasket materials. The score marks made cylinders. When the foam comes down on the cut
by previous impressions on the carrier material allow the material, it will deform into the K.O. hole while
gasket material to compress below the edge of the rule tending to grip the web to the K.O. board. The
producing slight attachments at each point where the rectangular foam pad becomes a “universal” K.O. plug
cutting edge intersects with a score mark on the carrier due to its ability to take the shape of any configuration
material. This problem is not as apparent on gasket of K.O. hole.
materials which fracture easily.
f. Spring fingers can be used to “flip” parts out of web.
Often this is useful for scatter packaging and where the
Feed Speed: machine does not have to stop for offending a stack of
The feed speed must be set so that the centers do not move papers.
excessively out of place during acceleration and de- g. Put a loop in the material (up or down - depending on
acceleration. The maximum feed speed will be determined how the part fits into the web) with the loop between
by the type of material being cut, and the type of carrier is the second and third roll feeds. As the part starts to
relied upon to hold the gasket material in place. make the sharpest bend in the loop, often times it will
pop out of the web or may require some assistance via
Registration of Center Under Die an air blast, mechanical tap, etc.
If the press is equipped with photoelectric registration, the
front or trailing edge of the center can be detected so that h. Some parts which are extremely difficult to de-slug or
on the next progression of the belt, the center will be knockout can be cut and, if in strip form, put into piles
properly located in relationship to the cutting die. While where the parts can be picked out 25 or so at a time by
photoelectric registration is certainly not necessary, it is a hand or in a simple jig fixture.

sensitive jobs?
If all of the above fail, do it the usual way!
QUESTION: What are some of the techniques to use in ANSWER: The most straight forward way is to use a
successfully die cutting pressure sensitive materials and powered rewind stand just like a powered unwind stand but
super thin materials such as .005" mylar? with a reverse dancer arm. This would handle up to a 750
pound coil.
ANSWER: We recently ran an extremely interesting test For rewinding the scrap web on pressure sensitive
for a customer with .005" material. His theory was that it the best way we have found is to use a matrix rewinder
would fracture much like steel will in blanking, so with a similar to those typically found on rotary label presses. The
positive micrometer stop, we took the die down in .001" trick is to have a drive system that will apply constant
increments from the point the rule just made contact with tension and not break intermittent feed system works.
the surface of the material to the point we had a clean cut. Another alternative if the material coil is light
After penetration of .004", we had no cut at all but enough is to mount a horizontal spindle about two feet
at .005" we had a perfectly clean cut. Obviously, this above the third roll feed and drive it by a pulley and belt
particular material did not fracture as originally supposed. arrangement off the matrix rewinder air motor or by a
What the experiment demonstrated so graphically was the separate motor with a variable slip clutch.
importance of:
QUESTION: Is there a way to die cut acetates,
A The flatness and parallelism of the two platen surface polyethylene and similar plastics and get clean edges (no
and the die back up and cutting plate back up plates. fringe)?
They must be surface ground.
ANSWER: Of course there is, otherwise we wouldn’t have
B. The even height of the rule even thru sharp bends and asked this particular question. The best bet we have found
the specification of what rule to use in constructing is to use a heated platen that heats up the back of the rule
dies for this type cutting. to about 250oF. If higher heat is required, you have to
watch the type die board used as it may tend to scorch or
C. The absolute control of where the edge of the rule is at smell.
all times in relationship to the cutting plate. With hot rule there is a decidedly different cutting
sound in plastics than is experienced with the loud “pops”
We have seen other examples including die cutting from of cold rule. The rule tends to melt its way through the
the top and bottom on double sided .008" pressure sensitive material and gives a much cleaner cut. It also requires
in a steel rule two stage progressive die which has considerably less cutting pressure (up to 2/3 reduction)
reinforced the notion of the critical nature of controlling the which speeds up the production rate.
factors mentioned above. Where they are present, you can We have not done much experimenting with hot
achieve some amazing results at high production rates on rule and a programmed dwell but believe the dwell
jobs you might otherwise have turned down. capability could also be useful in running some jobs more
successfully.
QUESTION: What are the ways to rewind the scrap web
or a web of cut parts particularly when cutting pressure

CHAPTER 17
ROTARY DIECUTTING/SOFT ANVIL
General Information Regarding Soft Anvil Rotary Diecutters
Soft Anvil Rotary Diecutters
The following specifications cover soft anvil rotary diecutters primarily

used in the corrugated container industry. A typical installation includes
some combination of a feed unit, the rotary diecutter, and either a stacker
of folder gluer. The specification outlined cover the diecutter though they
may pertain to other stations.
The maximum and minimum width in the feed direction describes what size
blank the diecutter can handle running through the machine. Maximum and
minimum blank length cover the size of the blank across the machine. The
size of the machine indicates approximately what size blank the machine is
capable of handling. For instance a 66"/1.68m x 80"/2m machine can
handle a blank approximately 60"/1.5m in the feed direction and close to
80"/2m across the machine.
The maximum speed describes how many blanks each machine is capable
of diecutting each hour.
The maximum and minimum caliper describe what thickness of corrugated

each machine is able to handle.
The last section of this specification contains notes from the manufacturer.
In the surveys sent to the equipment manufactures, we included a section
for them to fill in additional information they wished to include. The
section contains the information provided by the machine manufacturer.

17-1.0
Maximum Minimum Maximum Minimum Maximum Maximum Minimum
Width Feed Width Feed Blank Blank Speed Caliper Caliper Notes
Direction Direction Length Length
Company:
Serenco 64" 14.5" 80" 20" .560" .010" 1
10,500
Product: SPH
Rotary Die
Model:
1626 mm 368 mm 2032 mm 508mm 14.22 mm .254mm
Size: 66" x 80"
Company: Serenco
64" 14.5" 110" 20" .560" .010" 1
Product: Rotary Die 10,500
SPH
Model:
1626 mm 368 mm 2794 mm 508 mm 14.22 mm .254 mm
Size: 66" x 110"
Company: Serenco
64" 14.5" 130" 20" .560" .010" 1
Product: Rotary Die 10,500
SPH
Model:
1626 mm 368 mm 3302 mm 508 mm 14.22 .254 mm
Size: 66" x 130"
Company: 60"
United Container Reg. Feed 15" 82.5" 20" .625"
Machinery 10,800 Micro
87"
Skip Feed
SPH Flute
Model: Flexus Or 1524 mm

Graphixmaster Reg. Feed 381 mm 2096 mm 508 mm 15.88 mm
Size: 66" x 85" 2210 mm

Skip Feed
Notes:
1. May also include a manual or computerized slotter unit.

17-2.0

Company: 60" Reg.

Feed 15" 107.5" 20" .625
United Container
Machinery 87" Skip 10,800 Micro
Feed SPH Flute
Reg. Feed 381 mm 2731 mm 508mm 15.88 mm
Graphixmaster
Size: 66" x 113" 2210 mm

Skip Feed
Company: 60"
Reg. Feed 15" 119.5" 20" .625
United Container
Machinery 87" 10,500 Micro
Skip Feed SPH Flute
Reg. Feed 381 mm 3035 mm 508 mm 15.88 mm
Graphixmaster
Size: 66" x 125" 2210 mm

Skip Feed
Company: Ward 61"

Reg. Feed 14" 83" 22" .562" .062" 1
82" 10,200
Product: Basix
Skip Feed SPH
Model: 13000 1549 mm

Reg. Feed 356 mm 2108 mm 559 mm 14.27 .254 mm
Size: 66" x 80" 20830 mm
Skip Feed
Company: Ward 61"

Reg. Feed 14" 113" 22" .562" 1
.062"
82" 10,200
Product: Basix
Skip Feed SPH
Model: 15000 1549 mm

Reg. Feed 356 mm 2870 mm 559 mm 14.27 mm 1.57 mm
Size: 66" x 113" 2083 mm
Skip Feed
Notes:
1. Basic roll to roll transfer machine. No computerization.
Full graphics capability up to six colors.
Pinstripper option.

17-3.0

Width Feed Width Feed Blank Blank Speed Caliper Caliper
Direction Direction Length Length Notes
Company: Ward 61"

Reg. Feed 14" 125" 22" .562 .062 1
10,200
Product: Basix 82"
Skip Feed SPH
Model: 16000 1549 mm

Size: 66" x 125" 2083 mm
Skip Feed
Company: Ward 61"

Reg. Feed 22" 83" 22" .562 .062 2
82" 10,200
Product: Verigraphix II
Skip Feed SPH
Model: 13000 1549 mm

Size: 66" x 80" 2083 mm
Skip Feed
Company: Ward 61"

Reg. Feed 22" 113" 22" .562" .062" 2
82" 10,200
Skip Feed SPH
Model: 15000 1549 mm

Reg. Feed 559 mm 2870 mm 559 mm 14.27 1.57 mm
Size: 66" x 113" 2083 mm
Skip Feed
Company: Ward 61"

Reg. Feed 22" 125" 22" .562" .062" 2
82" 10,200
Skip Feed SPH
Model: 16000 1549 mm

Size: 66" x 125" 2083 mm
Skip Feed
Notes:
1. Basic roll to roll transfer machine. No 2. Fully computerized
computerization. Vacuum sheet transfer
Full graphics capability up to six colors. Direct drive re-registration section
Pinstripper option. Direct drive diecut section
Six color capability
Hot air interstation drying with hot air final drying
in the re-registration section
Pinstripper option

17-4.0

Company: 62" Reg. 1, 2, 3

Göpfert 18" 95" 24" .300" .060"
66" Skip
Feed 10,000
SPH
Model: RDC Evolution 1580 mm
Reg. Feed 460 mm 2400 mm 600 mm 8 mm 1.5 mm
Size: RDC 16/24 1676 mm
Skip Feed

Göpfert 18" 110" 24" .300" .060"
66" Skip
Feed 10,000
SPH
Size: RDC 16/28 1676 mm
Skip Feed

Göpfert 18" 126" 24" .300" .060"
66" Skip
Feed 8,000
SPH
Size: RDC 16/32 1676 mm
Skip Feed
Notes:
1. As an option, there is a maximum width feed direction of 86" (2185 mm) possible by using skip feed.
2. Includes: SUN-Feeder, vacuum sheet transfer, direct drive system, complete CNC control, up to six color full graphic
capabilities.
3. Options: Direct drive slotting unit, transfer/drying section, RDC stacker.

17-5.1

Company: 78" Reg. 1, 2

Göpfert 28" 190" 40" .630" .080"
96" Skip
Feed 6,000
SPH
Model: RDC 2000 mm
Reg. Feed 700 mm 4850 mm 1000 mm 16 mm 2 mm
Size: RDC 20/48 2450 mm
Skip Feed

Göpfert 28" 198" 40" .630" .080"
96" Skip
Feed 6,000
SPH
Model: RDC 2000 mm
Size: RDC 20/50 2450 mm
Skip Feed

Göpfert 28" 218" 40" .630" .080"
96" Skip
Feed 6,000
SPH
Model: RDC 2000 mm
Size: RDC 20/55 2450 mm
Skip Feed
Notes:
1. Includes: SUN-Feeder equipped with 4 rows of rubber rolls.
2. Options: Prefeeder, slotting unit(s), stacker, RDC stacker.

17-6.1

Company: CORfine 1
Web-Fed Soft Anvil 66" .375" 78" 2" 300 FPM .500" .009"
Rotary Diecutter
Model: Standard
1676 mm 9.53 mm 1961 mm 50.8 mm 92.3 12.7 mm .102 mm
Size: 66" x 80" MPM
Company: CORfine 2
Web-Fed Soft Anvil 30" .375" 28" 2" 300 FPM .500" .009"
Rotary Diecutter
Model: Compact
762 mm 9.53 mm 711 mm 50.8 mm 92.3 12.7 mm .102 mm
Size: 37.5" x 30" MPM
Company: CORfine
Sheet-Fed Soft Anvil 64" 16" 78" 24" .625" .050"
Rotary Diecutter 5,000
SPM
Model: Econoline
1626 mm 406 mm 1981 mm 610 mm 15.86 mm 1.27 mm
Size: 66" x 80"
Company: CORfine
SPM
Model: Econoline
1626 mm 406 mm 2489 mm 610 mm 15.86 mm 1.27 mm
Size: 66" x 100"
Company: CORfine
SPM
Model: Econoline
1626 mm 406 mm 2997 mm 610 mm 15.86 mm 1.27 mm
Size: 66" x 120"
Notes:
1. Also available with 50" (1270 mm) and 90" (2286 mm) circumference die cylinders and with 90" (2286 mm) to 120"
(3048 mm) cylinder widths.
2. Also available with 10" (254 mm) and 20"(508 mm) die cylinder widths.

17-7.1
Maximum Width Minimum Maximum Minimum Maximum Maximu Minimum

Feed Direction Width Feed Blank Blank Speed m Caliper Notes
Direction Length Length Caliper
Company: McKinley Reg.Feed 61"

15" 80" 22" .562" .010"
Skip Feed 66" 8,400
SPH
Model: Reg.Feed 1549mm
381 mm 2032 mm 559 mm 14.27 .254 mm
Size: 66" x 80" Skip Feed 3099mm mm
Company: McKinley Reg.Feed 61" 2

15" 110" 22" .562" .010"
Skip Feed 66" 8,400
SPH
381 mm 2794 mm 559 mm 14.27 .254 mm

15" 130" 22" .562" .010"
Skip Feed 66" 8,400
SPH
381 mm 3302 mm 559 mm 14.27 .254 mm

15" 150" 22" .562" .010"
Skip Feed 66" 7,200
SPH
381 mm 3810 mm 559 mm 14.27 .254 mm

15" 170" 22" .562" .010"
Skip Feed 66" 7,200
SPH
381 mm 4318 mm 559 mm 14.27 .254 mm

17-8.1
Maximum Width Minimum Maximum Minimum Maximum Maximu Minimum

Feed Direction Width Feed Blank Blank Speed m Caliper Notes
Direction Length Length Caliper

15" 190" 22" .562" .010"
Skip Feed 66" 7,200
SPH
381 mm 4826 mm 559 mm 14.27 .254 mm
Company: Hycorr Reg.Feed 60.5"

12.5" 82" 18" .560" Micro
14.5" 10,800 Flute
Skip Feed 87" w/score/slit SPH
shafts
Model: ProGraphics & Reg.Feed 1537mm

HyGraphics 318 mm 2083 mm 458 mm 14.22
mm
Size: 66" x 85" Skip Feed 2210mm
Company: Hycorr Reg.Feed 60.5"

12.5" 112" 18" .560" Micro
14.5" 10,800 Flute
Skip Feed 87" w/score/slit SPH
shafts
Model: ProGraphics & Reg.Feed 1537mm

mm
Company: Hycorr Reg.Feed 60.5" 1

14.5" 135" 18" .560" Micro
Skip Feed 87" 10,800 Flute
Reg.Feed 1537mm
SPH
Model: ProGraphics &
mm
Company: Serenco Reg.Feed 64" 2

14.5" 130" 20" .560" .010"
Skip Feed 82" 10,500
Reg.Feed 1626mm
SPH
Model: Centurion
369 mm 3302 mm 508 mm 14.22 .254 mm
Notes:
1. Without score/slit shafts or creaser/slotter section.
2. Fully computerized, vacuum sheet transfer, direct/servo drive diecut section, six color capability, hot air/IR drying .

17-9.1
Maximum Width Minimum Maximum Minimum Maximum Maximum Minimum

Feed Direction Width Feed Blank Blank Speed Caliper Caliper Notes
Direction Length Length

14.5" 110" 20" .560" .010"
Reg.Feed 1626mm
SPH
Model: Centurion
369 mm 2794 mm 508 mm 14.22 .254 mm

14.5" 130" 20" .560" .010"
Reg.Feed 1626mm
SPH
Model: Centurion
369 mm 3302 mm 508 mm 14.22 .254 mm
Notes:
1. Fully computerized, vacuum sheet transfer, direct/servo drive diecut section, six color capability, hot air/IR drying .

17-10.1
CHAPTER 18
FLUTED PAPER
General Information Regarding Fluted Paper
Corrugated Flute Chart
E-Macro
E-Micro
N-Opt
A-Opt
C-Opt
B-Opt
N-Std
A-Std
C-Std
B-Std
Flute
Flute
Height .260 .177 .158 .142 .140 .098 .097 .053 .044 .030 .020 .020
Inches
Flute
Per 24.6 35.4 37.7 39.4 38.6 46.9 46.9 84.7 89.9 128. 170 140
Foot 1
Take
Up 1.54 1.55 1.49 1.45 1.42 1.32 1.30 1.30 1.25 1.23 1.24 1.20
Factor

R0
CHAPTER 19
LASERS
General Information Regarding Dieboard Cutting Lasers —
Flat Bed and Rotary
The laser (Light Amplification by Stimulated Emission of

Radiation) to cut steel rule die board was introduced
to the diemaking industry in the late 1960’s with the
ability to cut flat dies only. Lasers for producing
rotary dies were developed in the late 1980’s. These
computer controlled machines provide greater speed
and accuracy over jig saw systems.

Recommended Laser System Standards and Capacities
Compiled by Dave Forstrom [formerly of] Lasercut, Inc.
A Laser Dieboard system should consist of the following:

X-Y Positioning system (Cutting table)
Rotary table (either stand-alone or in combination with the flat positioner), if
applicable.
Beam Delivery System
Laser resonator
Water Chiller (for the Laser)
Exhaust System
Either a PC or Machine Control to accurately move the positioning system in
accordance with the geometry of a CAD or Software program.
A PC computer to process CAD data
A “Post Processing” system to enable conversion of a CAD or other data exchange
file (such as DDES or DXF) to code that can be processed and run by the laser
system.
Imbedded parameters to properly cut all sizes and types of dieboard as well as
other materials that may be used in the diemaking process.
Components
X-Y Position Table
Table Capacities: Dieboard Use only ........... 500 lbs.

Complete system to be used for both dieboard
and steel ....................... 1500 lbs.
Drive Mechanism: Ball Screws (precision ground) - Minimum 1.5" Dia. Way Strips
Through hardened tool steel. All table bearing surfaces should be
covered to protect from cutting debris.
Cutting Speeds: The following is based on 2 pt kerf, 2200 Watts in Maple board:
Max cutting speed (Dieboard) - 100 ipm (inches per minute)
Max. OA Cutting Speed (While maintaining Geometry) - 350 ipm
Fast Traverse (non-cutting moves) - 1000 ipm
Accuracies: Repeatability ± .0005"

Dynamic Accuracy ±.002"/ foot + .005" OA
Squareness ±.001"
Beam Absorption: Target Plates in the bottom of the table to absorb the beam after it has
cut through the dieboard should be a minimum of .250" (¼") thick.

Exhaust: A minimum of two (2) exhaust vents on the table (one on each end)
and one (1) in the beam delivery to evacuate smoke and cutting
debris from both under and above the material being cut.
Rotary Positioning Table
Accuracies: Repeatability ±.005"

Positional in both axis' + .005
Cylinder Sizes: System should be able to cut the following sizes: (diameters)
7" 9.5" 10.125" 10.5" 11.5" 14.125" 14.188" 14.5"
15.25" 16.125" 17" 19.188" 20.438" 21.25" 21.563"
22.25" 26.5"
Center support of
the Dieboard Shell: Method varies between system manufacturers - Center support of the
board is necessary and critical to holding dimensions of the cut die.
Counterbore Tool: Optionally, the system should have an integrated (controlled by the
program) drill head to counterbore bolt holes.
Beam Delivery System

The beam delivery system consists of the optics and cutting head that directs the laser beam
from the output of the laser to the cutting table.
For dieboard cutting it MUST have the following:

A full retract mechanism to lift the entire cutting head up and out of the way for
purposes of fast traverse (non-cutting moves).
A motor or servo to control nozzle stand-off from the dieboard (omnidirectional)

which is controllable from the dieboard program.
A 5" focal point lens. ( The 5" lens is the most commonly used, however, a 7½"
lens is acceptable although it will slow the cut rate by approx. 10%).
A nozzle tip with an aperture of between .040-.060" dia. The size of the aperture
will vary slightly depending on the laser being used.
A surface following mechanism that will ride on the surface of the dieboard and
maintain a constant stand-off distance of the nozzle tip.

Laser Resonator
The Laser resonator used on a laser dieboard system is a matter of choice. The higher the
laser power, the faster the cutting rates in dieboard and, if necessary, the thicker the steel it
will cut (blanking fixtures etc.).
Dieboard Feed Rate

Laser Pulse CW Maximum Steel Thickness
500 watt 15 ipm 20 ipm .125"
750 Watts 25 ipm 35 ipm .250"
1000 Watts 35 ipm 45 ipm .375"
1500 Watts 50 ipm 60 ipm .500"
2000 Watts 60 ipm 70 ipm .500"
2200 Watts 85 ipm 100 ipm .625"
This table is only a guide to approximate thicknesses and feed rates and does not list all
intermediate laser powers available. The most common laser used for dieboard purposes is
2200 watts. The laser modes most commonly used in a dieboard system are 0-0 (Gaussian)
and 01 * (Donut).
It is possible to cut dieboard with as little as 250 watts, however, feed rates will be approx.
6-10 ipm.
Water Chiller
All lasers in the power range of 250-2200 watts require a cooling circuit which runs
refrigerated water through a heat exchanger in the laser and keeps the resonator cool. The
water chiller should be “closed loop” meaning that it recycles water from a tank or
reservoir.
Flow rate will vary from 1 gpm on very low power systems to as much as 20 gpm on
higher powers.
Exhaust System
Laser dieboard systems should be exhausted:
From under the cutting surface (which is where most of the smoke will accumulate)
Somewhere above the surface of the dieboard (in the vicinity of the cutting head)
On a normal sized table (approximately 50 x 100) there should be a minimum of two (2)
exhaust outlets under the work surface and one (1) exhaust outlet above the work surface.

State and local codes will dictate how and where the smoke is exhausted. In most localities,
exhausting to atmosphere (directly out of the building) is still permitted.
If this is not the case, the exhaust must be filtered for particulates. Due to the unusual
composition of dieboard smoke (creosote, etc.) it is very difficult to filter.
Recommended method is by electrostatic filter.
Machine Control System

On a dieboard system, the control MUST be able to vary both the focal height and feed in a
minimum of four directions (±X and ±Y).
There are two common methods of control of the movement of the positioning system and
laser interface:
PC Control
The PC Control simply uses an ordinary personal computer as the method of control
of the system. All system variables are stored on its hard drive and communicated to
the system direct wire interface to the servos.
The programming and tables in a PC control are written in standard computer

languages (C+, C++, etc).
Machine Control
A machine control handles the use of variables in the control to supply directional
changes in feed rate and focal height as well as the interface to the laser and
positioner.
The programming is NC machine code (G codes etc.).
Post Processor
Both methods require the use of a Post Processor to convert the CAD drawing to code that
will run the laser system.
The post processor must be able to:

Supply data to the system regarding directional feed rate and focal height infor-
mation to the laser system. The system must be able to automatically cut with
different feed rates and focal heights in a minimum of four directions (±X and
±Y). If the laser system will not do this, it is unacceptable for cutting die kerf.
Convert “data exchange” formats from outside sources (DDES, DXF etc.)

Allow the operator to choose the type and thickness of dieboard to be cut and
automatically adjust the parameters on the laser for that choice.
If the system is capable of cutting steel, parameters for types and thicknesses of steel
should also be included.
Safety Considerations
There are three significant areas of concern regarding the safe operation of a laser cutting
system:
Exposure to the laser beam. The laser cutting process is a thermal process - the laser
beam is very intense head (up to 22,000 C). This is capable of causing 3rd degree burns
and can cause deep burns and cuts in the human body.
Electrical Hazards. A laser beam is generated by exposing the laser gases to very high
electrical voltages (up to 25,000 volts). These voltages are present inside the laser resonator
when the system is running.
Pinch points. All laser systems have either a moving table or a moving gantry which
creates “pinch points” where, if care is not taken, an arm or leg can be caught and pinched
or crushed.
Recommended Interlocks:
An interlock is a safety switch that automatically shuts down either part or all of the system
if it is tripped. A laser dieboard system should have interlocks for the following:
All dieboard systems available today are Class IV systems which means that they are
not fully enclosed - only the area around the beam delivery is enclosed. It is possible
to stand in front of the system and reach the beam delivery area where the beam
exits the system and cuts the dieboard. The beam delivery cabinet door should be
interlocked so that access is restricted.
Because the laser beam is delivered through a beam delivery system which
physically rides on the dieboard, contact with the laser beam is unlikely. If,
however, the beam delivery is raised or the beam delivery moves off the board,
exposure is possible. The beam should be interlocked when the beam delivery is
in the raised position.

All systems cut within a specified work area (the travel limits of the table).
Normally, if the program tries to cut outside these limits the system will be
interlocked so that it will be stopped. In any situation where the movement of the
axis stops unexpectedly, the laser beam should be interlocked so that it turns
off.
The laser resonator cabinet should be interlocked so that if it is opened while

the system is running, the laser will shut down. The laser will normally have a
“service mode” that allows access while running.
If there are Pinch Points on the moving table or on the gantry, interlocks should be
provided either in the form of bump rails or interlocked floor mats.

General Information Regarding Lasers
Rotary Laser Technology
Note: This article reprinted from IADD’s The Cutting Edge, November 2001
Written by Tommy Moore, Stafford Cutting Dies, Indian Trail, NC, USA.
The use of laser technology to produce rotary A laser is a devise that creates and amplifies a
dieboards has revolutionized our industry and narrow, intense beam of coherent light.
promises to be a great benefit for years to come.
Atoms emit photons; we see it every day when the
Laser history and mechanics “exited” neon atoms in a neon sign emit light.
Normally they radiate their light in random directions
Lasers were first introduced as a tool for at random times. The result is incoherent light, a
diemaking in the mid-70s. Lasers began to replace the technical term for what you would consider a jumble
standard hand sawing, which was both time of light going in all directions.
consuming and labor intensive. These lasers were
typically 300 to 400 watts and limited to cutting only The trick in generating coherent light of a single
flat dieboards. Today in the diemaking industry, there or just a few frequencies going in one precise
are roughly 500 to 600 lasers in use worldwide, with direction is to find the right atoms with the right
an estimated 80 to 100 to be sold this year. These internal storage mechanism and create an environment
lasers vary in power from 300 to 5000 watts, with the in which they can all cooperate to give their light at
ability to cut flat and rotary dieboards. These same the right time and all in the same direction.
lasers are also used to cut a wide variety of materials.
Some examples would be plastics, phenolics, Mounting the dieboard
aluminum and even steel. The first step in using a laser is to mount the
Lasers are basically made up of three parts: dieboard. The laser I’m most familiar with drills bolt
holes in the die board; then the dieboard is bolted to
1. The laser cavity. This is where the actual laser collars. The collars are metal discs with a diameter
beam is created. equal to the diecutter cylinder. They have threaded
holes that are used to bolt the dieboard to the laser.
2. A CNC controlled movement system that There are many ways laser manufacturers secure
moves either the laser head or the substrate to be cut. dieboards, such as straps or pins. All of these methods
Many rotary lasers move the laser head in the x-axis can be equally effective.
across the wood, while the wood itself is moved in the
y-axis around the cylinder. Many flat lasers move The laser software shows me where the collar
only the substrate in the x and y axis. Any bolts will be located, by use of a laser light. This is
combination of movements are possible and available. done so the collars can be moved into their proper
position. Next the dieboard is placed on the collars
3. The last part is the chiller. A chiller is basically and secured with side pins; the bolt holes that are on
a large radiator that sends coolant through the laser the collars are drilled and the die bolts are inserted.
cavity. There are two types of chillers to choose After the collar bolts are drilled and bolted, the
from, one that is kept inside and one outside, remainder of the bolt holes that do not fall on collars
according to the user’s needs. are then drilled. This is one of the ways laser
Some of you may ask what exactly is a laser. The manufacturers choose to put bolt holes in the dies.
letters L A S E R are actually an acronym for Light Each laser manufacturer can explain his way of
Amplification by Stimulated Emissions of Radiation, mounting dieboards.
although common usage today is to use the word laser
as a noun rather then an acronym.

The cutting process instead of burning a straight line, the laser burns a
series of connected holes. This gives the burnt line a
Once you’ve finished mounting the dieboard, ribbed effect, like a saw cut, creating more friction
you are ready to begin the cutting process. With the to hold the steel rule in place.
customized software provided with lasers today, it
only takes a few key strokes and the laser is doing Lasers also have the ability to burn a line in two
the work that used to take an experienced diemaker passes. Using this method, the laser cuts a rectangle
hours with a hand-held jigsaw. for every line. By using less power at a higher rate
of speed, it will keep the widening at the middle of
How does this cutting process work? We have the cut at a minimum.
discussed that a laser’s job is basically to generate a
high intensity coherent beam of light. This is Both pulse burning and two pass cutting can be
achieved by sending a high energy stream of use together to create a consistent, easy-to-maintain
photons (light) across a specific mixture of CO2 kerf width.
(carbon dioxide), nitrogen and helium. This process
is performed in a reflective chamber called the laser FAQs
cavity. This is where the coherent beam is produced Now I would like to answer a few frequently
and from there focused through a series of lenses asked questions about laser die making:
onto the workpiece surface. The focused beam then
burns/cuts the workpiece and ejects the waste with Q: Are the gases used to run a laser expensive?
pressurized gas.
A: No. For a laser that runs for ten to twelve
The cut made by a laser is called the kerf. The hours a day, the gases would cost about $350.00US
kerf of a laser differs from a cut made by a saw. per month.
The kerf is narrower at the top and bottom of the
cut with a slight widening in the middle. Kerf width Q: How difficult is it to train someone to
at the top of the cut can be adjusted by varying the operate a laser?
focus of the laser beam. Focus the beam higher, and
the kerf is wider; lower, and the kerf is narrower. A: Someone who has basic knowledge of
The bottom of the kerf can also be easily adjusted computers and diemaking can be trained to burn
by simply varying the speed of the laser across the dieboards in only a few days. Burning metal and
work piece; faster, and the kerf gets narrower; other materials may take longer.
slower, and the kerf gets wider. Q: What type of maintenance does a laser
When cutting dieboards with a laser, kerf width require?
must be carefully monitored. If the kerf width is too A: Most of the maintenance on a laser is
narrow, you will be unable to install the steel rule. keeping the laser clean. The lenses must be kept
If the kerf width is too wide, the steel rule could fall very clean, and the smoke residue will need to be
out. This can become costly, with material waste or cleaned several times a day. This only takes 15 or
very unhappy customers. Some of the variables that 20 minutes. Oil replacement and internal lubrication
could alter a laser’s kerf width are dieboard density, are also required per the manufacturer’s
thickness and the amount of moisture it contains. specifications.
Another way to help minimize the effect of the
kerf is to use a pulse burn. When pulse burning,

Q: Are there lasers that will burn both flat and Q: What are the pros and cons of the inside and
rotary dieboards? outside chillers?
A: Yes, these lasers use a mirror to direct the A: Inside chillers are not subjected to bad
laser beam to the flat or rotary movement system. weather and are easy to perform regular
This is very helpful, because while you are burning maintenance on, provided you have available space
a die, you can be setting up another. for the large unit. Chillers take in air to cool the
coils; this air is heated in the process and must be
Q: Are special CAD systems needed to prepare vented from inside a building. This can create a
a file for the laser? negative airflow in a building and should be
A: CAD programs are typically provided with considered before the purchase of a chiller.
the laser. It is extremely important that all files sent Q: How do you check the width of the kerf on
to the laser be free of double lines and that all of the the top and bottom of the dieboard while it is on the
line types are correct. Another important thing to laser?
consider about your CAD system is if it has the
capability to produce files for a rule processor. This A: A tool that is the desired width at the end can
is important because the same CAD file used to be inserted into the laser cut line to help judge if the
make the laser file is used to make the processor line is the proper width.
file, assuring proper lengths and bridge placement.
This article was intended to give a basic
Q: Are there different settings for every understanding of lasers and how they work and
different thickness of wood? perform in today’s diemaking industry. I encourage
everyone to visit the representatives who market
A: Yes, the power used and speed that the laser lasers. More information is available through the
burns must be set for every different material cut. various laser manufacturers as well as the IADD.
These settings are saved on the software so they can
be recalled whenever that material is cut again.

for
Dieboard Cutting Lasers - Flat Bed and Rotary
Flat bed
Specification U.S. Metric Notes
Tolerance Tolerance
Positional +/- .001" +/- .083 mm
Accuracy per foot of table travel per meter of table travel
Repeatability +/- .0005" +/- .0125 mm
Rotary
Specification U.S. Metric Notes
Tolerance Tolerance
Positional +/- .005" +/- .127
Accuracy
Repeatability +/- .005" +/- .125 mm

19-2A
2 — check with your supplier.
Closer tolerances may be available
CHAPTER 20
MISCELLANEOUS
for
Printing, Diecutting and Embossing
Print to Cut
&
Emboss to Print
Overall Registration Tolerances
The following specifications have been compiled from a survey made to

converters in the folding carton industry. The results shown are the consensus of
this survey.
Print to Cut Emboss to Print

Registration Registration
Standard Tolerance for +/- 1/32" +/- 1/64"
Sheet Fed Press +/- .8mm +/- .4mm
Standard Tolerance for +/- 1/32" +/- .020"
Web Fed Press +/- .8mm +/- .5mm
Standard Tolerance for +/- 1/64" +/- 1/64"
Web Fed Rotary Press +/- .8mm +/- .4mm
Note: Tighter tolerances may be achievable by individual converters.

for
Overall Press Tolerances

General Information Regarding Rotary Precision Machining
Rotary Precision Machining Offers Alternatives to Diemakers
Note: This article reprinted from IADD’s The Cutting Edge, February 2001
Written by Rick Clay, Reliable Steel Rule Die, Chicago, IL, USA.
Rotary machining is not a new concept. In fact, it We are also researching the use of the machine to
represents the standard in nearly every industry manufacture counter plates, something we’ve always
demanding accurate, cost-effective material removal. outsourced in the past. While our demand for
Yet, for all of its proven attributes, this popular routing counterplates doesn’t begin to compare with that of
method was never accepted by the diemaking folding carton houses, it remains an area of interest for
community as a feasible means of generating dieboards. us, and we plan to explore it fully. And because we’re
The general consensus was that drill bits were simply a specialty shop—our niche lies in multiple up,
not durable enough to withstand the intense pressures one-of-a-kind dies rather than high-volume production
necessary to produce accurate die production tools. dies—we are researching a variety of additional
application options, as well… many outside of our
So it was with great interest that Reliable and other industry. We expect these opportunities to open the door
IADD members attended the Association’s September to new business for us, and ultimately help Reliable
1999 Annual Meeting in Chicago, where we were Steel Rule Die grow.
introduced to a brand new version of rotary machining.
One of the speakers presented an overview of his Advantages of Rotary Machining
company’s newly developed die tool production system.
We learned that it uses a routing process with carbide Such versatility was an important consideration in
bits that cut slots in plywood dieboards and other base our decision to invest in rotary precision machining.
materials. Bringing previously outsourced capabilities in-house via
one machine has enabled Reliable to save in several
This rotary system works by machining two layers ways. We’ve reduced our outsourcing fees by 80 percent
of board in a mirror image of one another and then and reduced die tool delivery time. And because we can
putting them together to form a kind of “sandwich.” zone off the vacuum table to hold even small sections of
They are glued together and placed in a high-pressure wood, wood waste is minimized, which reduces our
vacuum to flatten and hold the boards until set. The overall lumber costs.
process allows diemakers to produce very flat, stable
boards quickly and inexpensively. We saw this as an Other factors contributed, as well. Rotary machining
opportunity, because it meant that shops like ours would is a very environmentally friendly process; there are no
have a viable alternative to manual jigsaw operations emissions to exhaust. Unlike most diemakers in the
and laser burning. Chicago area, we’re located within city limits, which
makes us vulnerable to EPA regulations. And as
We installed the technology at Reliable in July 2000, everyone in this business knows, exhaust systems are
and have since used it very successfully to generate expensive. Also, despite its mechanical nature and the
flat-bed steel rule dies for a wide range of applications, amount of moving parts on the machine, the system
including printed materials, display and requires exceptionally little maintenance. Because it is
point-of-purchase work, folding cartons, decals and an affordable technology, a smaller die shop like
various crack-and-peel labels, and gaskets. We’re Reliable can bring various die tool production
currently using it to produce 90 percent of our capabilities in-house.
dieboards, as well as female and male stripping fixtures.
We find the system works especially well in generating
multiple cavity dies and large rectangular dies, and the
53.25" x 101.75" table easily handles a 96-inch board.

General Information Regarding Rotary Precision Machining
I mentioned earlier that the system works by as many jobs through the shop on a weekly basis with
machining two layers of board. A lot of good things less overtime as we did during 1999, one of our most
happen as a result of machining separate layers and then productive, but labor intensive, years ever. The system
bonding them together to form one dieboard—most is certainly fast enough for us. As a matter of fact, it
notably, greater stability. When you work with a natural routs the boards so quickly, we can’t get all of the CAD
product like wood, it’s very common for the boards to programs laid out quickly enough to keep it running
warp or twist. And it’s difficult to anticipate the continuously through an eight-hour shift. Plus, we’re
direction of twist. With the two-layer process, even if now able to produce stripping boards and other tools
warping does occur, because the layers are mirror much more economically, and therefore compete more
images of one another, those twisting forces are offset, effectively in those areas.
so the boards tend to be much flatter.
We can also better serve our customers in a number
Finally, the fact that the company offering this of ways, beginning with improved cost control.
technology is backed by a global corporation with Although we’re experiencing cost increases on many die
proven successes in revolutionizing other industries elements, including wood, rules and punches, this
made us feel very comfortable. Knowing they have the technology is allowing us to absorb those costs
resources and technical staff to fully support the internally… meaning we can hold our prices down for
business and the technology was a definite selling point longer periods of time without passing incremental
for us. We appreciate such stability. We’ve been in increases on to the customer. Furthermore, because we
business since 1947, and we’ve succeeded by acquiring now have automated in-house die tool production
the technology necessary for us to be competitive and capabilities, we can generate tools faster—obviously, we
allowing us to constantly improve our products and can rout a dieboard significantly faster than we can
services. Rotary machining has enabled us to reach an manually saw it—and retain higher quality control.
important milestone in terms of what we can offer our
customers. And while many of our customers may not have yet
noticed the steel rules are held more tightly in the
How Rotary Machining is Helping Our Business finished dieboard, we have. Again, the mechanical
nature of rotary machining—the use of solid cutting
The timing of this technology’s arrival at Reliable bits—tends to produce a highly consistent kerf line
proved critical for us. Less than three weeks following width. We like the fact that it creates a much tighter,
the machine’s installation in our facility, one of our key more controlled line. The rule doesn’t pull out or flex as
diemakers (in charge of jigging) suddenly passed easily. It sits more securely, and the integrity of the
away—leaving us short-handed and without the benefit wood is maintained, making it easier and faster to
of his lifelong expertise. Yet, it seemed almost as re-rule. We’ve re-ruled plenty of rotary-machined
though his spirit entered the machine, because we didn’t dieboards in the last several months—some customers
miss a beat. Our current shop foreman, who trained bring their boards in once a week—and they’re holding
with this gentleman on the system, just stepped right in up just fine.
and began processing dieboards almost immediately. So
the reduction in manpower never affected our The bottom line? We invested in rotary precision
productivity. Since then, we’ve cross-trained several of machining at a time of critical need at Reliable; it’s been
our staff on the machine, including my partner, and a lifesaver for us. It offers a lot of bang for the buck,
we’ve chosen to fill the vacant position to serve other and we believe it will pay for itself quickly. We see only
needs within our company. good things coming from it… for us and the rest of the
industry.
Thanks to the speed of this machine, we easily run

General Information Regarding Combo Dies, Full Class A Dies and
Blanking Dies
Description of Types of Hard Tooling
Note: This information provided by Richard Clements, Technical Manager,
Ken Die Cutting Supplies, Inc., Carson City, Nevada, USA.
A Combo Die consists of half male/female and half Stop blocks:

steel rule or a machined punch. This tool cuts interior
accurately and the exterior at steel rule quality. These protect the die from over stroking and
damaging the tool.
The Full Class “A” cuts with interior/exterior shear
cuts and includes stripper plate. This tool cuts both the Upper die shoe:
interior and the exterior very accurately.
This plate holds the die punch, males and the stripper
Blanking Die has only the male/female portion. This plate.
tool cuts the slug which is usually the part needed.
Lower die shoe:
Hard Tooling Die Nomenclature:
This plate holds the female.
Stripper plate:
Ball bearing bushings:
This is a solid machined plate backed up by die
These are used when there is high tolerance between
springs for a positive removal of die cut part from the
the male/female to prevent contact and also for a long
punch. This plate is used in combo dies as well as full
die run.
class “A” dies. the part is put back into the web.
Standard bushing:
Shedder plate:
The standard bushing is used when a lower tolerance
A plate is in the upper male punch of a Class A die to
between the male/female is not required and a short
remove the die cut part and then put it back into the
die run.
web.
Pin/Post:
Male/Perforator:
The pin/post enters the bushing for proper alignment
The male is the interior punch which may be a shape
before the male(s) enter the female.
or a diameter that has to enter into the female.
Die life:
Female/Platen:
Die life is the amount of vertical shape the die has.
This plate is on the bottom of the die set and it
The greater the die life the more the slug has to travel
contains all the diameters and/or shapes for the male/s
before exiting.
to cut through and the outer die punch to cut against.
Lift rings:
Female:
Used to lift the die when moving.
The female has the same shape as the male for which
it must pass through.

Blanking Dies
Shank/Spud: Set-Up Block:

Used to attach to the ram of the press. This block is used with a feeler gage to adjust the
press for proper engagement.
Stroke (Inches):
Up front information needed for hard tooling
The amount of movement the press has in vertical quote:
motion.
The basic price includes only a minimum required die
Punch: set to fit the die and material being cut. This die will
This is the outer portion of the tool usually a steel rule have a standard pin and bushing and none of the
die or a machined punch. options The type of press being used (can only be a
reciprocating not a clamshell)
Punch retainer plate:
1. What is the material being cut.
This holds all the males in location for exact
A. Can a sample of the material be supplied.
alignment to enter the female.
B. Is the material being cut face up or face
Sub plate:
down.
Used to make up distance for proper shut height.
C. Is there a liner being used, if so what is the
Die springs: thickness.
Die springs are of exceptional quality for use in the D. What is the thickness of the material being
return of the stripper plate or the return of the upper cut.
die shoe.
2. Tool Design Information:
Spring return:
A. What is the quantity of your order.
If the die set is to be returned under its own power.
B. Maximum opening of the press.
This aids in having not to bolt the upper die plate to
the press. C. Minimum opening of the press.
Parallels: D. Is there a scrap hole in the press, if so
what are the dimensions.
To lift the die set for scrap removal when there is no
scrap hole in the press. E. Are parallels needed to lift the die for slug
removal.
Pilot Punch:
F. Is there a bolt pattern or machined ledges
Used to locate the material when doing progressive for mounting needed.
cutting.
G. Shank/Spud to mount into the ram needed
if so what diameter and length.

Blanking Dies
H. Length and width of the die set (or use B. Stripper Plate (otherwise customer to
manufacturer’s recommendation). install their own ejection).
I. Thickness of upper and lower plates (or use C. Material Guides.
manufacturer’s recommendation).
D. Material Supports.
J. Die Life (or use manufacturer’s
recommendation). E. Lift Rings.
K. Stroke (Inches). F. Parallels (if so how many or use

manufacturer’s recommendation).
L. Is the press to return die to its start height
or use a spring return. G. Shank/Spud.
M. Direction of material feed. H. Special Hole Patterns Or Machined Ledges

For Mounting.
N. Material width.
I. Spring Return.
3. Options:
J. Ball Bearing Bushings.
A. Stop Blocks.

International Association of Diecutting and Diemaking
Standard Specifications Committee
Chair: Don Skenderian
Committee Members: Mike Adams Robert Larson

David Bialoglow Edward Martin
Parker Corts Joe McDowell
Dennis Garrity Randy Norman
Don Greenwood Rae Pfaff
Joe Holden Dan Valmassei
Ken Holliday Peter Witzig
Richard Kengott
Chief Executive Officer: Cindy C. Crouse, CAE
Please enter your comments (or additions to tolerances) on this sheet for review by the
Specifications Committee and possible publication in future revisions. Attach additional pages if
necessary.
Name:
Company:
Address:
Phone:
Thank you,
Don Skenderian, Chair

Standard Specifications Committee
Return To: IADD, 651 W. Terra Cotta Ave., Suite 132, Crystal Lake, IL 60014 USA
FAX: 1-815-455-7510

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IADD

Revision 1, June 2002

Table of Contents ii-iv

Chapter 1-- Flat Rule Rev.

Chapter 2 -- Rotary Rule

Chapter 4 -- Counter Plates

Chapter 5 -- Cutting Plates

Chapter 6 -- Chase Back Plates

Chapter 7 -- Ejection Material

Chapter 9 -- Automatic Rule Bending Machines

Chapter 10 -- Makeready Systems

Chapter 11 -- Clicker/High Dies

Chapter 12 -- Rotary Diecutting

Chapter 14 -- Thermal Dies

Chapter 17 -- Rotary Diecutting / Soft Anvil

Chapter 18 -- Fluted Paper

Comments/Corrections Form Inside Back

The disadvantages of ground edge rule are:

(Continued on next page)

IADD Product Information 1-1 R0

Cutting Edge Angle:

1. What rule, if any, is currently being used?

(Continued on next page)

IADD Product Information 1-2 R0

The standard bevels, 52 & 60 can be used up to 50 pt. board.

IADD Product Information 1-3 R0

Soft Used only where extreme bends are necessary.

IADD Product Information 1-4 R0

Cutting Rule Faces

IADD Product Information 1-5 R0

Cut Edge Fidelity

Cut Angle Fidelity.

(Continued on next page)

IADD Product Information 1-6 R0

Length of Secondary Bevel

IADD Product Information 1-7 R0

(Continued on next page)

IADD Product Information 1-8 R0

IADD Product Information 1-9 R0

IADD Product Information 1-10 R0

(Continued on next page)

IADD Product Information 1-11 R0

IADD Product Information 1-12 R0

Flat Cutting Rule - Side Bevel or Center Bevel - Under 2"/50mm

IADD Recommended Specifications 1-1-13A

IADD Recommended Specifications 1-1-14A

Flat Cutting Rule - Side Bevel or Center Bevel

IADD Recommended Specifications 1-1-15A

Creasing and Folding of Paperboard

IADD Product Information 1-16 R0

IADD Product Information 1-17 R0

Creasing Rule Height:

When matrix material is applied to the cutting plate before channels

Height = cutting rule height (-) minus thickness of board.

When counter system is used.

Height = cutting rule height (-) minus thickness of board

Creasing Rule Width:

2 pt. Creasing rule is generally used on stock up to .025"

IADD Product Information 1-18 R0

Flat Creasing Rule

IADD Recommended Specifications 1-19A

Flat Creasing Rule

IADD Recommended Specifications 1-1-20A