How to choose a suitable large die-cutting machine?
blog 2025-11-27 23:03:22 17
How to choose a suitable large die-cutting machine?
Large die-cutting machines have long been an indispensable core tool for the printing, packaging, and special processing industries. From the rounded corners of children’s books to the special-shaped production of exquisite cards, and then to the precise punching of smart cards and game cards, they can be seen in many sub-sectors. A good large die-cutting machine needed for production can not only make the product feel better but also reduce production costs through more efficient work, making the enterprise more competitive in the market. When purchasing, many manufacturers are often lost in the maze of parameters. This article will start from the real production needs, get rid of the complicated data, and then sort out the selection logic from a professional perspective to help you find the best equipment solution.
Find out what materials are needed for production. This is the first step in choosing the right tool.
The cutting performance of large die-cutting machines is directly related to the flexibility of the materials used in production. The density and toughness of materials are different, and the equipment needs different methods in terms of pressure control, mold adaptation, and material transportation. If the equipment is selected at random, problems such as burrs on the cut and material damage are likely to occur, which will waste funds and reduce product quality.
The selection logic of paper materials needs to be different according to different grammage. 60-150 g/m² coated paper and matte paper are often used for the inner pages of children’s books and periodicals and for making ordinary cards. This material is thin and light, so it is easier for the machine to feed paper accurately, preventing stacking or paper-feeding deviation. Currently, it is best to use a flat-bed press with a precision feeding system. Because the pressure output is stable and controllable, it helps to keep the incision flat and reduce paper waste. Cover paper and greeting card paper are both relatively thick, with a weight of between 150 and 300 grams, and are relatively hard, requiring the equipment to output greater pressure. A heavy-duty flatbed or rotary die cutter is best. The robust frame of this machine ensures that the pressure is fully transmitted and the cutting is done correctly.
Cardboard materials usually weigh between 300 and 1500 g/m². Extra-thick cardboard of more than 600 g/m², such as hardback book covers and 3D greeting cards, is a good way to test whether the equipment is strong and stable under pressure. When purchasing, pay attention to whether the body of the equipment is strong and whether the pressure adjustment range is wide enough. The heavy-duty flatbed die cutter’s rigid frame design and wide pressure adjustment range allow it to easily cut through extra-thick cardboard. Its unique die-cutting fixing method can also reduce die-cutting loss and make weak parts more durable.
The problem with cutting plastic materials such as PET and PVC is that they tend to bounce back. Thin film plastics (≤0.5 mm), such as label film, need to be cut quickly and continuously. The best choice is the electric eye tracking system and high-speed rotary die cutting machine. The line contact cutting method makes the cutting surface smooth and the material is not easy to stretch. The thick plastic sheets with a thickness of 0.5~5 mm, such as smart card substrates, have a high rebound rate, and the equipment needs to have good pressure-holding capacity. High-precision hydraulic presses can control the cutting depth well and avoid burrs or dimensional deviations in cutting by adjusting the pressure in real time. It should be noted that high-quality large die-cutting machines can be used for a wide range of tasks. By changing the die and adjusting the parameters, the precise blanking can be carried out on special materials such as book paper or filter paper. This allows you to use one machine for multiple purposes and improve equipment utilization.
Focus on core performance: Jump out of parameters to see the truth.
Many people are concerned about the die-cutting pressure, precision, speed, and other issues in the working performance of large die-cutting machines. In fact, these parameters need to be carefully selected according to the production needs, not “the higher the better.”
When selecting the die-cutting pressure, the most important thing is to “adapt to the material and product” rather than blindly pursuing high pressure. For example, when making ordinary cards, excessive pressure will accelerate the wear of the die-cutting tool and may also leave indentations on the edge of the product, affecting the appearance. When cutting ultra-thick composite materials, insufficient pressure will lead to incomplete cutting. High-quality equipment can use mature hydraulic or servo drive technology to finely adjust the pressure. It can also adapt to the cutting needs of different materials. Its durable design ensures long-term stability at high pressure and minimizes equipment downtime.
The quality of the product depends directly on the accuracy of the die-cutting. This is especially true for products with very strict size requirements, such as smart cards and game cards. A small mistake can cause subsequent steps to fail to proceed as planned. The guarantee of precision is not based on one component but on the cooperation of the entire system. For example, the combination of a precision ball screw and linear guide rail can reduce the transmission gap, and the precise drive of a servo motor can correct the position in real time. Some high-end models are even equipped with a CCD visual positioning system, which can automatically find the product position, adjust the cutting coordinates, and ensure that the size error of each product is controlled within a very small range. The products punched out in this way have high punching precision and no burrs. High-precision cutting can also make the edges of children’s books, hardcover cards, and other products feel softer and improve customer experience.
The relationship between the size of the table, the die-cutting speed, the production capacity, and the product specifications should be considered. The size of the table should meet the maximum product specifications while leaving enough space for positioning and fixture installation. For example, when making large covers for hardcover books, a large table can reduce the number of times of typesetting, and the single cutting efficiency is higher. When making small cards, a table of appropriate size can be used for multi-line typesetting, increasing the number of cards made per unit time. The speed and accuracy of die cutting need to be balanced. If the speed is too fast, the accuracy may decrease. The choice needs to be balanced according to the product requirements. For small-batch customized products, the speed can be reduced to ensure accuracy. When mass production is carried out continuously, the speed should be increased as long as the accuracy meets the standard. The 7.5 kW servo system uses high-quality components and can find the balance point between speed and accuracy as time changes. This ensures production efficiency while maintaining quality.
How much automation do you need to meet your production and efficiency needs?
The level of automation in a large die-cutter directly affects its operating efficiency, the cost of employing workers, and the quality consistency of the products. Different levels of production require different types of automation setups. If you blindly pursue high automation, the equipment may be idle, but if you go the other way, the production capacity will not be able to grow.
Semi-automatic die-cutting machines are suitable for new businesses or small-batch customized products. Their main advantage is that they are not expensive to start up and run. Manual feeding and receiving can easily cope with the production needs of multiple varieties and small batches, such as making samples for specific markets and customizing cards. However, it should be noted that the efficiency of semi-automatic models depends largely on the manual proficiency of the operator, and the labor cost is high in the long run. These models are most suitable for enterprises with a monthly production demand of less than 50,000 sheets.
The fully automatic die-cutting machine is more suitable for medium-sized enterprises with a monthly output of 50,000 to 300,000 sheets. This machine has automatic paper feeding, automatic waste removal, automatic material collection, and other systems. This machine has automatic paper feeding, automatic waste removal, automatic paper collection, and other systems. From feeding to finished products, the whole process does not require manual participation. Not only is the production efficiency 2-3 times higher than that of the semi-automatic mode, but also the standardized process reduces the errors of manual operation. High-quality fully automatic models also have all the extra functions needed. For example, the automatic sorting system can collect finished products in order or by category according to production needs. The customized finished product collection method can be directly used for the next packaging step. The automatic fault detection system can detect the equipment status in real time, alarm, and quickly find the problem, reducing the maintenance time.
The linked production line is the key to improving the core competitiveness of large enterprises with a monthly output of more than 300,000 sheets or large-scale production. This system is based on the fully automatic die-cutting machine, combining multiple processes such as hot stamping, embossing, sorting, and stacking to achieve a highly efficient production mode of “one-time paper feeding and multiple processes completed.” For example, when making high-end greeting cards, the linked production line can do both hot stamping and die-cutting. This improves the quality of the product and also improves efficiency. The built-in intelligent visual inspection system can automatically eliminate defective products and further improve the product qualification rate. The mature linkage production line can also provide a completely customized overall solution and carry out personalized design according to the production process and workshop layout of the enterprise. Make the production links connect smoothly.
Long-term operation view: hidden but not negligible value
Buying a large die-cutting machine is not just a one-time cost but also a long-term value. The stable operation of high-quality equipment reflects its technical advancement. For example, the models produced by local Shenzhen enterprises have been tested in overseas markets and have accumulated many years of technical experience, making them more adaptable and reliable. This means that production will not be frequently stopped due to equipment failure.
The most important thing to do to reduce long-term costs is to make the equipment durable. Using high-quality body parts and core components can make the equipment last longer and reduce the frequency of replacement of worn parts. For example, the 7.5 kW servo motor adopts a mature design, which not only ensures the smooth operation of the system but also consumes less energy. In the long run, it can save a lot of energy costs. In addition, equipment that can be used for multiple purposes helps to better utilize production capacity. One machine can punch and cut a wide variety of items, including books, filter paper, and cards. This way, the equipment is not idle when producing products.
In addition, do not forget the value of personalized services. For example, for the punching and cutting needs of special products, suppliers can provide personalized services such as mold customization and parameter debugging. The customization of the finished product collection method can be matched with the company’s existing packaging process, reducing the cost of secondary handling of products. For users in other countries, the perfect after-sales support and technical services can help solve the equipment maintenance problems in multinational operations and ensure smooth production.
Procurement Summary: Decision-Making Method Returning to the Essence of Demand
The most important thing when choosing the right die-cutting machine is to return to the fundamentals of production needs. First, make sure you know the characteristics and specifications of the main production materials. Then, depending on the scale of production capacity, decide how much automation is needed. Finally, from the perspective of long-term use, the stability, durability, and hidden value of the equipment are examined. When producing children’s books, cards, and other items, the punching accuracy and product texture of the equipment are very important. For large-scale production, the degree of automation and linkage adaptability are more important.
Before purchasing, it is best to determine what you really need. This includes the main material and size of the product, the monthly production capacity target, the connection requirements of the current production process, and the long-term planning of product iteration. On this basis, communicate with suppliers in depth, conduct on-site inspections or sample cutting when necessary, and feel the working status of the equipment. Remember, the best large-format die-cutter is not the one with the highest specifications, but the one that can meet your production needs and continuously add value to your business.