Rotary vs. Flatbed Die Cutting: Which Should You Use?

Flatbed digital cutters are post-press processing equipment, which is used in the advertising printing graphic industry. Flatbed digital cutters called digital sample cutters, automatic die-cutting indentation machines, flat die-cutting machines, and similar functions, are for advertising printing material cutting.

 

Die-cutting is often used to create unique shapes from rubber, plastic, and foam materials.

 

Before starting a die-cutting project, it's important to discuss all the specific project requirements - including whether rotary or flatbed die-cutting is best for the job. Each cutting method has its own unique advantages, depending on product size, cost, and material.

 

What is rotary die-cutting?

Key benefits: maintains tight tolerances, ideal for kiss cutting

 

Best for high-volume orders

 

How it works: Rotary die-cutting is a highly accurate cutting method that is very cost-effective on high volume orders and generates less waste than other methods. As shown in the video, the machine is fed a roll of material, which is then passed through a roll die. This cuts the desired shape from the material and disposes of the waste in a collector.

 Flatbed Digital Cutter

What is flatbed die cutting?

Key Benefits: Provides more cost-effective options and reduces tool and die costs

 

Best for General cutting and low volume orders

 

How it works: With flatbed die cutting, material shapes are stamped out using steel ruler dies and hydraulic presses. This method allows for easy removal of holes and webs from the part, along with quick changeovers for efficiency.

 

Flatbed die cutting is the process of cutting or perforating the desired shape from the material using a hydraulic flatbed press.

 

In general, flatbed die-cutting is suitable.

 

Consistent cuts for small lot items

Larger size products

Cutting products from sheet material

High precision cutting of materials over 1/8" thick

Projects where tooling costs must be kept to a minimum

Multi-process projects; rotary die-cutting can be combined with coating, embossing, creasing, laminating, and other processes

Flatbed Digital Cutter

 

Presses for flatbed die-cutting

Flatbed die-cutting presses allow for very high-precision cutting of materials thicker than 1/8 inch. Unlike the circular cuts produced by rotary die-cutting presses, flatbed cuts are perpendicular to the death bed. The cut is sharper and more defined. Flatbed dies cutters can accommodate larger materials. Steel ruler dies are easier to change, so they are more efficient when cutting multiple shapes.

 

Compared to other die-cutting processes—e.g., rotary die-cutting and laser cutting—flatbed cutting is more suitable for processing thicker material, producing larger parts, and completing small orders or short production runs. However, while flatbed dies cutting demonstrates some advantages over rotary die cutting and laser cutting, some manufacturing applications are better suited to these other die-cutting processes, such as high-precision, intricate design, or large-run part production. The requirements and specifications demanded by a particular die-cutting application—e.g., materials, sizing, tolerances, costs, turnaround times, etc.—help determine the type of die-cutting process most suitable to use for it.

 

Die-cutting with Gunner products

Gunner's team of engineers ensures that the right die-cutting machine is used to meet your project needs. Our die-cut products from a variety of flexible non-metallic materials are available in continuous rolls, sheets, or individual parts to meet your unique application.

 

Ready to get started? Visit our website to find your material and contact us about your next project.

Benefits of Flatbed Cutters

The art of cutting doesn't need to be complicated, time-consuming, or expensive. With current flatbed cutter technology, you can easily achieve a higher level of finish. In this article, we'll give you an in-depth look at the benefits that flatbed cutters can bring to your business.

 

1. When size matters

Jobs come in a variety of sizes - and sizes - and they all require proper finishing. However, small, complex jobs and larger-than-life jobs require a lot of time, effort, and skill to complete manually. This is where a flatbed cutter can "come in handy" and save you not only valuable time but also money.

 

With current technology, you can get excellent precision with automated cutting systems. Gunner's flatbed cutters come in a range of sizes to serve everyone, so how do you determine which size is best for your type of business?

 

Ask yourself the following questions.

What is your core business; are you focused on a specific application or as many as possible?

How flexible do you want to be in providing new applications/solutions?

What material sizes do you process most often?

How much do you want to invest?

How much space do you have for a flatbed cutting machine?

Is there anything else you would like to consider?

If you need personal advice to help you make a decision, please feel free to contact our experienced sales team.

Flatbed Digital Cutter

2. Cut multiple jobs with the same flatbed cutting machine

If you are eager to grow your business, you must be prepared to take on any job. Whether that means cutting 1.000 magnetic stickers of the same size for an upcoming sale or promotional board material, you need a system that works for any job, every time.

Often, flatbed systems can accommodate a variety of tools through a modular tooling system that allows for the customization of tools to each individual's needs.

In this way, an endless number of substrates can be handled in an instant. The following list is just a sampling of what Gunner flatbeds can accomplish for you.

Plastic

Vinyl stickers

Paint protection film

Blackout film

Digital printing and cutting

Logo graphics

Custom decals and labels

Reflective sheeting

3. Optimize your workflow with these media handling features

Did you know that your future Gunner flatbed cutter has many features to improve your workflow? With these features, spending a week on a job will be a thing of the past!

 

Get your production up and running with the following standard features.

Vacuum system to hold the material in place: Thanks to this system with air suction, the material is pressed against the table during processing to ensure a smooth and easy finish.

Conveyor system for controlled media feeding: A conveyor belt fixed around the table combined with pneumatically driven media clamping allows you to cut large lengths of material and run your production in high volume.

Reel support system for reel-to-reel operation: Combined with the conveyor system, the reel support system is ideal for handling rolled material.

Let us help you find the best flatbed cutter for your project. When you contact us, please provide your detailed requirements. That will help us give you a valid quotation.