Die Making
Overview: Forming Steel Rule Dies into Different Shapes for the Die Cutting Process
What is Die Making?
Die making is the process of preparing the metal cut out to get a print piece into a specific shape. Essentially the die making process must be completed before the die cutting process can happen. The die making process consists of three main components: the die base, the steel rule die, and the rubber/foam ejection. Starting with a bendable metal strip known as a steel rule, the sharp cutting die is formed into a desired shape. The steel rule can vary in height, thickness, and overall shape of the cutting edge depending on the print material. A laser is then used to cut a slot in the dieboard to insert the steel rule. After, a foam or rubber ejection is added along the steel rule to help push the cut-outs from the tool for removal. It’s then inserted into a die cutting machine to cut a print piece into its desired shape.
At Phillips, we manufacture our own steel rule dies using state-of-the-art CAD design software and hardware. We also provide design services and sample construction to assist in creating your unique concept.
Die Making Considerations
The thickness and compressibility of the print material needs to be considered to better determine the steel rule die’s thickness and cutting-edge length for an effective cut.
The intricacy of the design is intercepted by CAD design software to make the steel rule die for the print design cut-out. The software then takes the producibility, features, and functionality into consideration. As a result, some adjustments may need to take place.
The typical timetable for steel rule die making is anywhere from one to three days. This can make it difficult to get tight deadlines out on time, so be sure to work that into the project timeline.
Benefits of Die Making
The presses in die making operate at high speeds, which in turn produces faster production times.
When a die needs a tweak, changes can be made the same day with Phillips for extra flexibility and convenience.
Phillips provides in-house die making. Other print finishers outsource die making, which would require a two-to-three-day deadline project extension.
Die Making Capabilities
Steel rule dies manufactured in house
CAD design services & sample making
“I have used many other print finishing partners, but Phillips is the most trustworthy and my go-to for honest, quality work. I never feel like I am second rate.”
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