From design to finished product, the whole process of the customized die-cutting machine is introduced in detail.
blog 2025-11-25 19:45:11 25
From design to finished product, the whole process of the customized die-cutting machine is introduced in detail.
Customized die-cutting machines are an essential part of the production of children’s books, smart cards, game cards, and other products. The precision of its stamping effect and the rapid automation process directly affect the quality of the finished product. We are a custom die-cutting machine manufacturer and developer based in Shenzhen. We know that standardized and professional workflow is the key to ensuring the good operation of the machine. This article will disassemble the entire process of a customized die-cutting machine from drawing design to mass production. It will also introduce how it achieves core functions such as accurate feeding and automatic collection, as well as the technical reasons behind its unique texture and durability.
Step 1: Drawing design and engineering evaluation
The main value of a custom die-cutting machine is the “customization.” Drawing design and engineering evaluation are the basic steps to ensure that the customized solution fully meets the needs. At this time, the key transformation is to fully combine the customer’s production environment, processing materials, final product requirements, etc., and decompose the needs into the implementation of the plan.
Before the mapping, the technical team will communicate with the customer many times to ensure that they know what kind of finished product the customer wants. For example, when making children’s books, the thickness of the paper, the size of the format, and the arc of the rounded corners must be in place. When making smart cards, it is necessary to ensure that the chip position is correct and the punching method is correct. At the same time, it is also necessary to confirm the customer’s needs for production capacity, workshop layout, supporting processes (such as whether it is necessary to support the hot stamping process), etc., so as to provide a full picture for the next design. The design team will use CAD and other professional software to create three-dimensional drawings based on the demand analysis. These drawings should not only reflect the main structure of the equipment but also the accurate position of the core components, such as the installation position of the 7.5 kW servo motor, the running track of the automatic sorting mechanism, etc. In this way, the equipment can be used for multiple purposes, not only for punching and cutting books, but also for punching and cutting different materials such as filter paper.
Engineering assessment is the process of checking the feasibility of the design scheme, and it is also the most important step to ensure the durability and good operation of the equipment. Technicians will consider three aspects: the degree of coordination of materials, the degree of coordination of technology and the degree of cost control. In terms of materials, high-strength alloy parts are selected according to the characteristics of the stamping materials to ensure the service life of the equipment. In terms of technology, if the customer needs to be equipped with the hot stamping process, the coordination rhythm of the hot stamping module and stamping module will be checked in advance to avoid process conflict. In terms of cost, the structural design is optimized to achieve the best cost performance on the premise of meeting the performance requirements. Once the evaluation is passed, the drawings will be sent to the customer for confirmation. This will be the basis for the final production.
Step 2: Making the mold—what is the “heart” of the customized die-cutting machine?
The custom die-cutting machine is the most important part of the production process. The mold is the “heart” of the machine, and its accuracy directly affects the quality of the stamping product. For example, the manufacturing process of the mold determines whether the stamped product has burrs and whether the size is correct. We have established a whole-process control system for mold processing, from material selection to precision testing.
The type of die material you use depends on how you need to treat it. High-hardness alloy steel is usually used when stamping thin materials such as children’s books and cards. This ensures the sharpness of the mold and extends its service life. Surface-hardened custom steel is used to reduce mold wear from special materials such as filter paper. The CNC machining stage comes after the material cutting. The five-axis linkage precision milling CNC machine tool accurately converts the dimensional parameters on the drawings into physical molds. The machining accuracy can be controlled within ±0.01 mm. The key point of this link is to design the cutting edge of the mold and adopt the circular arc transition treatment to ensure the uniform stress during stamping and avoid burrs.
After the mold is processed, it needs to undergo multiple precision tests and fixation. The three-coordinate measuring instrument first detects the key dimensions of the mold to ensure that it is completely consistent with the drawings. Then, the mold is placed on special test equipment that simulates the actual stamping scene for testing. Finally, the stamped samples are tested to ensure that they meet the requirements. If any dimensional deviations or burrs are found, they will be immediately corrected by laser grinding or other methods until the mold is accurate enough. It is this strict production standard that enables the customized die-cutting machine to accurately punch and cut without burrs.
Step 3: Machine debugging and test cutting are key steps to ensure everything is correct.
After the mold is made, it must be debugged and test-cut on the machine. This is an important step to ensure the synchronization of equipment, molds, and production needs. This will directly affect the stability of mass production in the later stage. This link will test the automation performance, precise control, and process synergy effect of the equipment.
The first step in machine debugging is to calibrate the mechanical structure. Technicians ensure the feeding mechanism, punching mechanism, and receiving mechanism of the equipment work together by adjusting the coaxiality of each mechanism. Through professional software, the running parameters of the core 7.5 kW servo system are set to find the best balance point between the feeding speed and the punching frequency. This ensures the accuracy of the feeding. This debugging directly guarantees the processing quality of products with high requirements for dimensional accuracy, such as smart cards and game cards. The automatic material collection and waste removal system was also tested. The sorting mechanism is set up to ensure that the finished products are collected in the order or category selected by the customer. This will improve production efficiency by ensuring that waste is discharged in real time.
The trial cutting stage uses the raw materials actually used by the customer for trial production. It is usually divided into two parts: small batch trial cutting and continuous trial cutting. Small-batch trial cutting is to test the accuracy of a single process, such as punching size, burr condition, finished product texture, etc. The continuous trial cutting will run for 1 to 2 hours to test the stability of the equipment, such as whether the servo system can run continuously, whether the mold is durable, and whether the automatic sorting system is accurate. During the trial cutting process, technicians will keep a close eye on the process, record data, and make timely adjustments once problems occur. For example, the problem of burrs is solved by adjusting the pressure setting, and the adjustment of the position of the sorting sensor makes the classification more accurate. Only when the finished product qualification rate reaches 100% and the equipment is running without problems can the next step be carried out.
Step 4: Mass production and quality control to ensure stable output
Batch production is the last step in the manufacturing process of customized die-cutting machines. A perfect quality monitoring system is the key to ensuring the consistency of equipment operation and the consistency of products. Based on our years of experience in serving global customers, we have created a three-dimensional quality control model of “real-time monitoring + fixed-point sampling + full traceability.”
Before mass production, technicians will set the operating procedures of the equipment according to the trial cutting parameters, such as the feeding speed, stamping pressure, sorting frequency, etc. Ensure that the equipment runs according to the best plan. The equipment’s own intelligent monitoring system will collect important data in real time during the production process. These data include the working current of the 7.5 kW servo motor, the pressure change of the stamping mechanism, and the accuracy rate of finished product sorting. If the data is abnormal, the system will immediately alarm and stop production. This is to prevent the mass production of unqualified products. The scrap removal system will also continue to work, removing the stamping scrap in time to prevent the accumulation of scrap from affecting the accuracy of the equipment. Quality inspection is mainly divided into two parts: first-piece inspection and process sampling inspection. Full-time quality inspectors conduct first-piece inspections on the first piece of finished product of each batch. They check the dimensional accuracy, edge smoothness and texture, etc. Only after the inspection is qualified can mass production be carried out. The process sampling inspection is to extract 20 pieces from every 500 pieces produced. The dimensions are measured with precision measuring tools, and the burrs and surface quality are checked with a visual inspection system. For production scenarios involving hot stamping, the accuracy and adhesion of the hot stamping position will be checked again.
The complete workflow of customized die-cutting machines always revolves around the three major needs of “precision, stability, and efficiency.” From the careful planning of the drawing design to the quality inspection of mass production, all are included. Based in Shenzhen, we are committed to building a customized die-cutting machine with strong technical strength. It has the main advantages of being unique, durable, and versatile. In addition, it can meet the specific needs of global customers by integrating customized overall solutions. Custom die-cutters help many industries run smoothly by stamping rounded corners on children’s books or carefully handling smart cards.