Cut through any challenge with rotary die cutting
We can produce a range of precision cutouts for custom packaging, labeling or masking applications. Projects can be produced in either a standard or clean-room environment. Most materials can be custom die cut or slit to your desired size and specifications.
Standard discs, dots and rectangles can be produced same day.
With many different manufacturing equipment options at our disposal, we select the fastest and most cost effective solution to meet your requirements. Working with our in house engineering team, we can scale from prototype and short runs to full production volumes.
As a part of the die cutting process, we can easily add split liners and pull tabs for easy handling and removal.
Given the diverse selection of materials we carry from our range of valued suppliers (we are a 3M Preferred Converter), our lead times are some of the best in the industry.
What is rotary die cutting?
Rotary die cutting is a fast, cost-effective manufacturing process used to cut parts from flexible films and adhesive materials. It involves the use of custom-engineered cylindrical dies mounted on a rotary press, which continuously converts materials into precise shapes.
Find out more in the next section.
Rotary Dies
The desired pattern is milled into a die, with the "rule" being the sharp cutting edge. Rotary dies come in two types: flexible and solid. Flexible dies, made from thin metal sheets, are more cost-effective and easier to produce but wear out quickly and are limited in the materials they can cut.
Solid rotary dies, made from a single cylinder, allow for deeper engravings and higher blade heights, making them suitable for thicker and multi-layered materials. Their durability is ideal for high-volume runs. Unlike flexible dies, which must be discarded when dull, solid dies can be re-sharpened and reused multiple times, extending their lifespan.
Rotary Presses
A rotary die cutting press uses multiple stations with spindles that determine the machine's maximum web width—up to 13 inches at CFS. Rolls of material are fed through the press, where different stations perform tasks like laminating, kiss cutting, and through cutting.
To form the die-cut shape, the material—typically laminated to a liner—passes between a cylindrical die and anvil. The die cuts through the adhesive layer while only "kissing" the liner. In some cases, the liner itself is slit to create a split-back liner for easy removal, which is also a form of kiss cutting. A final station may cut completely through both material and liner (where there's no adhesive), producing sheeted parts instead of rolls.
Rotary Die Cut Materials
Rotary die cutting is suitable for converting a wide variety of materials. We regularly die cut industrial masking tapes (such as green polyester, polyimide, and crepe), VHB tapes, medical tapes, and flexible materials up to 1/4" thick. As a 3M Preferred Converter, we maintain a large in-house material library and have access to hundreds of additional non-stock materials.
For more information on rotary die cut services from CFS or to speak with one of our knowledgeable professionals please feel free to contact us or simply request a quote for your project.