What are the differences between die-cutting methods: flatbed, roll-to-roll, and laser?

High-speed. Accurate. Versatile. You want your die-cutting method to be able to meet your needs, as it鈥檚 an essential part of manufacturing. In reality, however, you may have to make some choices based on your project鈥檚 priorities. High precision or high volume? Ultra-high speed or intricate cutting? Low cost or low maintenance?

Before exploring the three most popular types of die-cutting鈥攆lat bed, roll-to-roll, and laser鈥攍et鈥檚 review what die-cutting is and why it鈥檚 so beneficial.

Basically, a die is a tool, usually made of metal, that cuts through materials (paper, plastic, fabric, adhesives, etc.) to create parts that are uniform in size and shape. Used to benefit many industries, die-cutting offers different advantages, depending on the type of project.

So, what is the difference between rotary die cutting and flat bed? And how does laser cutting differ from both? Now is the best point to provide a brief overview of the different methods.

? Flatbed die cutting: As the name implies, a hydraulic flatbed press pushes a blade to cut the material into the desired shape.

? Roll-to-roll die cutting: A cylindrical die with blades around the entire cylinder that cut shapes from the material moves in a circular motion. This efficient motion cuts many identical shapes as it rolls from roll to roll.

?Laser Die Cutting: Instead of using a steel blade to create the desired shape, a laser sears the material. This makes it easy to cut complex shapes into many materials, but the process can damage other materials and some adhesives.

Pros and Cons of Each Die Cutting Method

Now that you understand the basic mechanics of each method, let鈥檚 dive into the advantages of each method as well as the limitations of each method. Keep this in mind: like any manufacturing process, the most efficient method is usually the one that best fits the needs of your project.

Flatbed Die Cutting: Simple Can Be Useful

While it is the most basic method of die cutting materials, flatbed die cutting may be the preferred method for certain projects. The cutting dies are manufactured and placed in a hydraulic press, which allows it to cleanly cut thick and sheet materials. Flatbed die cutting produces simple shapes, similar to a cookie cutter.

Tooling can be changed easily and quickly, making flatbed die cutting the right choice for low-volume projects or if the product will not work well on a roll-to-roll or laser cutter.

Roll-to-Roll Die Cutting: Best for High-Volume Projects

Think of this method as the cookie-cutter approach of taking a flat bed and adding a rolling pin. A roll-to-roll die-cutting cylinder allows for a wide variety of continuous shapes to be quickly cut from material supplied in roll form.

The press鈥檚 roll-to-roll cylinder blades cut the material to precise lengths, maintaining precise tolerances through the use of servo motors to maintain alignment. Known for its durability, roll-to-roll dies can cut rolls of material to perfectly fit objects of the same size, a key advantage for parts in fields such as the medical, military and aerospace industries.

Laser Die Cutting: No Blade Required

Laser die cutting does not require any contact with the material, using a high-speed laser to make a variety of cuts. It is a highly repeatable process that can accurately cut extremely small details.

Laser die cutting is often chosen for precision cutting of flexible materials (tapes, rubbers, laminates), adhesives, and materials that would otherwise damage traditional die-cut steel. An example is converting a grinding wheel into a round shape suitable for a flat sander. These are cut with a laser because the sandpaper itself would quickly wear out a roll-to-roll or flatbed die cutting blade.

Which method is better, laser die cutting or traditional die cutting?

Traditional die cutting

Speed
Laser cutting is precise but not fast; it needs to adjust and follow the shape it is cutting. A roll-to-roll die is already set to the shape and can quickly repeat that cut over and over again.
Advantages: Roll-to-Roll Die Cutting

High Precision
Laser die cutting is well suited for precision and finishing of intricate, complex shapes; both roll-to-roll and flatbed are limited by how far you can place the blade.
Advantages: Laser Die Cutting

High Volumes
Cutting the same shape on multiple pieces of material isn't always easy, especially when the material is thick. When it comes to fast turnaround of large orders, lasers fall short.
Advantage: Roll-to-Roll Die Cutting

Cleanest Cut
The reason laser die cutting doesn鈥檛 win out here is laser ablation. A high-intensity laser beam melts or burns the material to get through it, leaving some residue at the edge of the cut.
Advantage: Roll-to-Roll Die Cutting vs. Flat-Bed Die Cutting

Prototype-Friendly
When rapid prototyping is needed, it鈥檚 easier and cheaper to use laser die cutting than to get and execute hard tooling. If you end up needing high volumes, invest in roll-to-roll die cutting.

Deep Cutting or Multi-Layer Cutting

Generally speaking, laser die cutting is not effective for thick materials and multi-layer materials. The laser is set to one cutting depth, while flatbed and roll-to-roll allow cutting of two layers, for example, but not a third.
Advantages: Roll-to-Roll Die Cutting and Flat-Bed Die Cutting

User-Friendly
Simple to train and easy to operate. Both flat-bed and roll-to-roll die cutters have more working parts. For example, the dies in a roll-to-roll die cutter need to be physically replaced after they wear, which requires operator training.
Advantages: Laser Die Cutting

Material VariationsLaser die cutting is more limited in converting materials than other methods. It also depends on the type of laser being cut. The wavelengths are different, so some materials鈥攃onductive materials, high-temperature plastics, polycarbonate, etc.鈥攃annot be effectively cut by many lasers. Advantages: Roll-to-Roll and Flat-Bed Die Cutting

Unique Challenges of Laser Die Cutting

When converting with roll-to-roll and flat-bed die cutting methods, the material itself remains unchanged; it is simply cut, removing what is not needed. As we have discussed, laser die cutting changes the physical condition of the material, which is something to consider.

Is the edge of the part being cut critical to its performance? Because, after the convert, if the laser burns the edge enough to change its properties, it may not be the best die cutting method for that part.

Wavelength is also a challenge with laser die cutting, making sure the material can be cut with the wavelength of a specific laser. If the material does not accept the laser well, no cutting will occur; if the material absorbs the laser too much, the material will burn.