Rotary die cutting is die cutting using a cylindrical die on a rotary press. A long sheet or web of material will be fed through the press into an area known as a “station” which holds a rotary tool that will cut out shapes, make perforations or creases, or even cut the sheet or web into smaller parts. A series of gears will force the die to rotate at the same speed as the rest of the press, ensuring that any cuts the die makes line up with the printing on the material. The machines used for this process can incorporate multiple “stations” that die cut a particular shape in the material. In each of these stations lie one or more of these geared tools or printing cylinders, and some machines use automatic eye registration to make sure the cuts and / or printing are lined up with one another when higher tolerances are required.
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The technique was invented by Simon François Ravenet, an engraver from France who later moved to England and perfected the process he called “décalquer” (which means to copy by tracing); it became widespread during the decal craze of the late 19th century.
Die cutting can be done on either flatbed or rotary presses. Rotary die cutting is often done inline with printing. The primary difference between rotary die cutting and flatbed die cutting is that the flatbed is not as fast but the tools are cheaper. This process lends itself to smaller production runs where it is not as easy to absorb the added cost of a rotary die.
Die cutting is the general process of using a die to shear webs of low-strength materials, such as rubber, fiber, foil, cloth, paper, corrugated fiberboard, paperboard, plastics, pressure-sensitive adhesive tapes, foam and sheet metal. In the metalworking and leather industries, the process is known as clicking and the machine may be referred to as a clicking machine. When a dinking die or dinking machine is used, the process is known as dinking. Commonly produced items using this process include gaskets, labels, corrugated boxes, and envelopes.
See also for more Postage stamp separation Steel rule die Cutting plotters References Bibliography Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003), Materials and Processes in Manufacturing (9th ed.
), Wiley, ISBN 0-471-65653-4.
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Dinking uses special dies called dinking dies, or hollow cutters. The edges of the dies are usually beveled about 20° and sharpened. The material is punched through into a wood or soft metal block in order to not dull the edges. The die may be pressed into the material with a hammer or a mechanical press.
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Die (manufacturing) Die cutting (shearing), the general process of shearing using dies Die cutting (arts and crafts) Die cutting (web), the cutting of shapes out of webs Die preparation of semiconductor chips Another name for die making Katanuki (Japanese, lit.
Die Cutting), a game where one cuts a shape out of a sheet of candy
Different variations of decals include: water-slide or water-dip; and vinyl peel-and-stick. A water-slide (or water-dip) decal is screen-printed on a layer of water-soluble adhesive on a water-resistant paper, that must first be dipped in water prior to its application.
A decal is composed of the following layers from top to bottom:
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This section may require cleanup to meet Wikipedia’s quality standards. The specific problem is: unclear descriptions of layer order and meaning of facestock, labelstock, and backing material. A diagram might help.
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Upon contact with water, the glue is loosened and the decal can be removed from its backing; overlong exposure, however, dissolves the glue completely causing the decal to fail to adhere. A peel-and-stick decal is actually not a decal as described above, but a vinyl sticker with adhesive backing, that can be transferred by peeling off its base. The sign industry calls these peel-and-stick vinyl stickers vinyl-cut-decals.
A paper or film face-stock makes up the top layer of the labelstock. The printing is done on the upper side of the facestock. An adhesive layer is applied to the bottom of the face stock. A silicone or release coating layer is applied to the upper side of the backing material.
A paper or film liner provides the bottom layer of the labelstock. An RFID circuit (chip and antenna) can be included in the paper or film face stock.
Dies used in rotary die cutting are either solid engraved dies, adjustable dies, or magnetic plate tooling. Engraved dies have a much higher tolerance and are machined out of a solid steel bar normally made out of tool steel. Adjustable dies have removable blades that can be easily replaced with other blades, either due to wear or to cut a different material, while magnetic plate tooling has a cylinder that has magnets placed in it, and an engraved metal plate is attached or wrapped around the base cylinder holding onto it by the force of the magnets.
Mass-production of vinyl decals starts with large rolls of vinyl sheet. Vinyl is fed through a plotter or large-format printer/cutter which prints the desired image and cuts out the desired shapes. Designs are typically created using specialized computer software and sent to the machines electronically. After the patterns are cut, excess vinyl on the sheet is removed in a process called weeding. Finally, a paper pre-mask can be applied to the top of the vinyl design allowing easy application of multiple letters and shapes.
Government agencies (and some Private Public Partnerships) use decals on vehicles for identification. These decals are referred to as fleet markings and are required by law on all fire and law enforcement vehicles in the US. Most fleet markings are created from reflective vinyl with an adhesive backing that is applied in a peel-and-stick manner.
1 Rotary die cutting 2 Dinking 3 See also for more 4 References 4.1 Bibliography
A decal (/ˈdiːkæl/, /dɪˈkæl/, /ˈdɛkəl/, /ˈdeɪkæl/) or transfer is a plastic, cloth, paper or ceramic substrate that has printed on it a pattern or image that can be moved to another surface upon contact, usually with the aid of heat or water.
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Decals are commonly used on hot rod automobiles and plastic models. They are also used on guitars as a way of personalizing them.
The word is short for decalcomania, which is the English version of the French word décalcomanie.
Notes on printing Inkjet printing Laser printing Photocopy Offset printing Embossing Thermal printing See also Bumper sticker Ceramic decal Country tag Dry transfer Lithography Sticker Wall decals References External links Look up decal in Wiktionary, the free dictionary.
Industrial Transfers and the Art of Decalcomania How to Install Vinyl Decals
1 Properties 2 Production process 3 Applications 4 Notes on printing 5 See also 6 References 7 External links
Die cutting started as a process of cutting leather for the shoe industry in the mid-19th century. It is now sophisticated enough to cut through just one layer of a laminate, so it is now used on labels, stamps, and other stickers; this type of die cutting is known as kiss cutting.