Rotary die cut advantages and disadvantages - Flexopedia

In flexography printing, die cutting plays an important role. With die cutting, the print job is faster and requires less hands-on effort, which can be difficult with miter saws and other cutters. Because die cutting eliminates the need for precision cuts, it is an efficient and accurate printing method. Furthermore, die-cut paper can be handled and printed on more easily due to its slimmer thickness. Lets look at the advantages and disadvantages of rotary die cut machine in detail.

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What is Rotary die cut?

Printing with rotary die cut involves cutting a die into a variety of shapes, such as circles, squares, and other patterns.

Compared to traditional printing methods, this allows the printer to produce intricate and detailed prints.

There are two types of rotary dies.

1. Solid die
2. Magnetic die

Advantages:

There are a variety of designs that can be printed using the rotary die cut, which is a simple, efficient, and affordable printing method.

The fact that rotary die cut printing produces more accurate cutting may make it a better choice for flexography printing.

As a result of die cuts, less offset is created, and the finish is more efficient.

Furthermore, die cuts can be customized to produce unique designs that are hard to replicate without special equipment.

Intricate designs and custom shapes can be created with rotary die cuts.

Rotary die cuts are ideal for those who want to create unique pieces since they are hard to replicate using other methods.

There are a variety of rotary die cutters available for small businesses and amateur printers.

Their affordability and ease of use make them an excellent choice for those who want the best results.

As rotary dies produce a precision product, they are a popular way to cut products.

Additionally, rotary die cuts offer many advantages over standard cutting techniques when it comes to response time and accuracy. 

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Disadvantages:

Although magnetic rotary die is less expensive than a solid rotary die, but the rotary die cut method has its own cost and is not feasible for small volumes.

It may be necessary to make specific settings in order to produce accurate prints with this product.

In particular, precision is a challenge when using the die cut feature.

Due to its die-cut feature, rotary die cuts may be less versatile than other printing options.

FAQs:

What is the difference between Rotary die cut and flexography?

Rotary die cut machines are used to cut intricate designs, while flexography is a printing process where images are reproduced using flexographic plates.

Conclusion:

Rotary die cut in Flexography is a process where high-quality images are cut out of flexible materials, such as vinyl and paper.

This method can be used to create intricate designs and patterns that would be difficult or impossible with other types of graphics production methods. 

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longlimb said:

Thanks for the articles dabob. And sorry for the vagueness of my needs. But I am truly starting from scratch here and not exactly sure what I should be looking for. We are a medium size shop. The largest press is 28". We do a ton of pocket folders but send them out to finishers out of town. I would say we average 2-3 PFs a week. Probably only 2-3 embosses a month though. And even less on foil. So not looking to find a piece of equipment to do foil stamping. Really our focus is diecutting with hopefully embossing.

The embossing we do is usually not a large area. Typically a logo on the front of a PF or the header of LH. So from the article, a cylinder press would be ideal with keeping the embossing area parallel to the gripper. Noting a flat bed would be ideal but not necessarily needed.

I guess with my prepress background I just have a hard time understanding the procedures/tasks of doing either diecutting or embossing on a cylinder press. MR times from switching from diecutting to embossing, etc.

Budget? Well that's always the million dollar question, right? We more like thousand dollar question for us. I would say $20K. Is that number ridiculous for a decent cylinder diecutter press?

I guess I should ask another question, where do I find one? Does anyone have used press companies they recommend? I've found a couple places but supply seems stark. I really like dixie reproductions but just worried about him finding me what I need.

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Ok lets take them in order 1st you don't need a press bigger than a 30" since your largest press is a 28. How long a run is your average PF? As to your experience . . . . I would highly recommend you find a person who has experience running diecutters/letterpress type of equipment - its a whole new world of printing than offset or digital. You would also need to find someone to make your steel rule dies for you. They might have an idea who might help you get started.

Budget .. . . as I recall our 30" was about $35,000 installed . . but that was several years ago and we are just outside San Francisco - you haven't said where you are so I can't hazzard a guess on what dealers you might have locally. You would also want to find a source for your embossing dies and they might be more help for information regarding embossing on a cylinder. Also if the most common product for this is P folders how are you going to glue them . . . it can be done by hand but that is really slow you might want to look at a folder/gluer to take this on.

So from here . . . your budget is on the low side . . you might get an old Mehile for that price but I don't know how much impressional strength a vertical Mehile has or how it would handle complex die shapes in the delivery. You are going to have to do some homework with someone experience in the art of diecuting before you leap off into the deep end. Good Luck . . . .

Ok lets take them in order 1st you don't need a press bigger than a 30" since your largest press is a 28. How long a run is your average PF? As to your experience . . . . I would highly recommend you find a person who has experience running diecutters/letterpress type of equipment - its a whole new world of printing than offset or digital. You would also need to find someone to make your steel rule dies for you. They might have an idea who might help you get started.Budget .. . . as I recall our 30" was about $35,000 installed . . but that was several years ago and we are just outside San Francisco - you haven't said where you are so I can't hazzard a guess on what dealers you might have locally. You would also want to find a source for your embossing dies and they might be more help for information regarding embossing on a cylinder. Also if the most common product for this is P folders how are you going to glue them . . . it can be done by hand but that is really slow you might want to look at a folder/gluer to take this on.So from here . . . your budget is on the low side . . you might get an old Mehile for that price but I don't know how much impressional strength a vertical Mehile has or how it would handle complex die shapes in the delivery. You are going to have to do some homework with someone experience in the art of diecuting before you leap off into the deep end. Good Luck . . . .

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