Star card Die Cutting Machine Equipment for Making Small and Large Batches of Cards
blog 2026-01-20 23:24:44 38
The popularity of crowdfunding and limited edition cards has changed the way cards are made.
The unique and scarce demand of the game card industry is ever-changing. The rise of crowdfunding and the popularity of limited edition cards are driving the printing industry to shift from the old model of one-time mass production to a flexible production model of small batches, multiple batches, rapid response, and accurate delivery. This change has brought new technical problems to the die-cutting machines used in the printing industry. It also promoted the development of special equipment more suitable for this trend. The Star Card die-cutting machine is one of the most important. Its main features of “short, flat, and fast” fully meet the basic needs of card making today.
From the perspective of the actual production scene of the industry, the main characteristics of the crowdfunding card are the unknown number of orders and the very specific needs. The order quantity of a single batch is usually between several hundred and several thousand sets. Production batches need to be adjusted according to the crowdfunding situation, and even personalized designs may be temporarily changed. Limited edition cards pay more attention to the accuracy and uniqueness of the finished product and are often made of a mixture of paper, film, soft magnetic sheets, and other materials. Some high-end limited edition cards also need to be made with special processes, which require very high die-cutting accuracy and card edge quality. The common problems of traditional die-cutting machines, such as burrs on the card edge and position deviation, can no longer meet these production needs.
The main advantage of the large continuous die-cutting machine used in traditional card production is its high efficiency in mass production. There are serious problems in the production scene of small batches and multiple batches: the time for machine adjustment and mold change is long. It usually takes 1-2 hours to adjust the machine when switching an order and 30 minutes to change the mold. The time spent on debugging the equipment is much longer than the time spent on actually producing crowdfunding, limited edition, and other orders of several hundred sets. This not only greatly increased production costs but also greatly delayed the delivery cycle, making it impossible to keep up with the fast-changing pace of the market.
According to industry data and market trends, the global crowdfunding market for game cards will grow at a rate of 42% per year by 2025. Small-batch orders (≤5,000 sets per batch) will account for 68% of the market, and limited-edition cards will account for more than 35% of the market. The global light die cutting tools market size will reach US$0.701 billion in 2024. It is projected to grow at a CAGR of 4.1% to reach .249 billion by 2031. The packaging and paper processing industries will be the largest application demand. These two major trends together indicate that small batches and multiple batches will become the most common way of card making in the future. Printing companies need die-cutting equipment that can respond quickly and accurately produce products in order to gain more market share.
The Star-Card die-cutting machine is a step-by-step feeding die-cutting machine manufactured in Shenzhen, China. It is designed for small batch orders, mainly for the global overseas market. Its original purpose was to solve the problems encountered by traditional die-cutting machines in flexible production. It is widely used in the production of various cards, such as business cards, smart cards, game cards, playing cards, animation cards, bank cards, star cards, etc. It can also make small packaging boxes, which can accurately feed materials, automatically collect materials, and automatically discharge waste. This makes it very suitable for the flexible production needs of the printing industry, especially for the personalized card collection market in Europe, America, Japan, and South Korea.
Mingxing card die-cutting machine fast debugging and preparation time optimization scheme
The main problem of small-batch and multi-batch production in the printing industry is the rapid change of orders and the short preparation time for production. The main technical advantage of the Starcard die-cutting machine lies in the efficient compression of debugging, mold changing, and preparation work through the optimization of structure and the upgrading of functions. Its technical features are “high efficiency, precision, and easy to use.” The following is a comprehensive interpretation of its main technical features and time-saving solutions from the technical and practical perspectives for the reference of printing enterprises.
The fast changeover adjustment speed is one of the most important technical features of the Star Card Die-cutting Machine. The changeover time is only 15 minutes, which is more than 70% faster than the old equipment. This advantage comes from the synergy of its two main technologies. First, it has a system for correcting and positioning the layout vision. This system is equivalent to the “high-precision electronic eye” of the equipment. It uses industrial cameras to take real-time photos of the positioning marks on the material and quickly calculates the deviation between the material and the preset coordinates through the pixel-level image processing algorithm. Then, the servo system drives the die-cutting knife holder to perform dynamic compensation, without manual calibration. This reduces the time for positioning and debugging of the die-cutting knife holder and keeps the positioning accuracy of the finished product within ±0.03 mm, avoiding the increase in the scrap rate caused by positioning errors. Secondly, the design adopts a stepping precision feeding process, which decomposes the feeding process into several precision steps. Each step is controlled by an independent servo motor, and the feeding accuracy can reach 0.01 mm. To complete the feeding system, you only need to call the preset parameter template when changing the machine. Debugging shortens the adjustment cycle and ensures the accuracy of the feeding, which ensures the quality of the subsequent die cutting.
Another important advantage of the Xingka die-cutting machine is that the mold-changing efficiency is higher. It adopts a lightweight wooden die design, and it only takes 2-3 minutes to replace the die, which is 90% faster than the traditional metal die replacement. The molds of traditional die-cutting machines are mostly made of metal, which is heavy and difficult to disassemble. It usually takes more than 30 minutes to replace a set of dies, and two or three operators are required to complete the replacement. The Star Card die-cutting machine uses wooden molds, which are only 1/5 the weight of traditional metal molds, and adopts a quick-buckle design. One person can complete the disassembly and assembly without any special tools. The equipment also has the function of mold parameter memory. When changing the mold, the equipment can automatically call the die-cutting parameters of the new mold without debugging again. This saves more time after mold replacement. Moreover, the cost of wooden dies is only one-third of that of traditional metal dies, which can help printing enterprises save on die investment. This is especially useful for small-batch, multi-specification order production.
The StarCut die-cutter has a number of important technical features that help improve die-cutting quality and speed. First, the die-cut products do not need to be nailed. Traditional die-cutting machines need to leave nail holes or connection points when die-cutting to prevent the finished products from falling apart and then manually remove them. This increases the time of the process and may damage the edges of the card. The Star Card Die-Cutting Machine can cut out finished products at one time with its precise die-cutting control and feeding design. No need to leave nail holes or connection points, saving time and ensuring the quality of the card edges, with no burrs or scratches. It fully meets the production standards of limited edition and high-end cards. Secondly, it has a 7.5 kW servo stamping power system; the stamping power is consistent and can be accurately adjusted without repeated manual debugging of the stamping pressure. This ensures the stability of the die-cutting quality and avoids equipment failure caused by improper pressure. It also reduces the time spent troubleshooting during the debugging process. The servo system consumes very little energy, meets the energy-saving standards of the global overseas market, and meets the environmental protection needs of overseas customers.
The Starcard die-cutting machine has strong adaptability and can be applied to a variety of commonly used card-making materials such as paper, film, and soft magnetic sheets. It is also very flexible in adapting to different materials. It can adapt to materials of different thicknesses and textures by simply changing the feeding pressure and die-cutting speed without replacing any equipment parts. It solves the problem that traditional equipment can only process one kind of material, reduces the preparation time for changing materials, and is very suitable for limited edition card orders that need to mix different materials. It can produce many different things, such as cards (smart cards, business cards, game cards, playing cards, anime cards, bank cards, star cards, etc.) and small packaging boxes. This means that printing companies can take on more orders.
The Star Card die-cutting machine has also been improved in terms of finished product processing and connection to the next process. The equipment has two types of material collection, which can be switched according to the order situation. One is the single-specification card collection method suitable for continuous production, which makes the finished products arranged neatly and orderly and facilitates subsequent packaging. Another method is to collect orders suitable for multi-specification mixed die-cutting by category. The equipment will automatically collect finished products of different specifications into different areas, without manual sorting. This saves a lot of time after production and makes the overall production process more efficient. The equipment also supports a complete solution for online back-end product packaging. After die-cutting, it can be directly connected with the packaging equipment, making the production process of “die-cutting-receiving-packaging” more efficient, reducing labor, reducing labor costs, and conforming to the trend of the printing industry toward automated production.
The Starcard die-cutting machine can also be used directly for customer proofing. After debugging, no additional proofing equipment is required to quickly produce samples. It shortens the response time for customer proofing, helps printing companies quickly understand customer needs, and makes customers more satisfied. In terms of actual operation, the equipment has a graphical operation interface, and important parameters are displayed in dynamic images. The operator only needs to set parameters, change molds, switch modes, and perform other operations through the touch screen. There is no need to understand complex visual algorithms and mechanical debugging tools. This reduces labor costs and errors caused by insufficient operator skills, making production preparation more efficient and stable.
On-site interview: a small card studio tells how they use the Star Card die-cutting machine to flexibly accept orders.
To ensure the Star Card Die Cutter was technically sound and useful, we spoke to a small card studio that focuses on crowdfunding and producing limited edition cards. The Star Card die-cutting machine, which is made in Shenzhen, China, and adapted to the global overseas market standards, has seen a significant increase in orders and profits since its introduction in early 2024. Its experience in using the machine is of great reference value to other similar printing enterprises.
The studio mainly takes orders for crowdfunding cards, limited edition game cards, and star cards at home and abroad, with a production volume of only 200 to 3,000 sets each time. Customers have very high requirements for the accuracy of the finished product, the quality of the card edge, and the speed of delivery. European and American customers require smooth edges and a position accuracy error of less than 0.05 mm. Japanese and Korean customers pay attention to personalization and diversification, and most orders are delivered within 7 days.
Before the studio had the Star Card die-cutting machine, it had been using traditional large die-cutting machines. They mainly have three problems: First, the order response time is long, the machine adjustment time is more than 1 hour, and the mold change time is more than 30 minutes. For small orders of 200 sets, the equipment debugging time accounts for more than 50%, and the production efficiency is very low. Second, the material adaptability is not strong, and special materials such as thin films and soft magnetic sheets cannot be used. These orders must be outsourced, which leads to high costs and uncontrollable quality and cycle. The on-time delivery rate is only 65%. Thirdly, the speed of proofing is slow, and it takes 1-2 days to complete a set of samples. As a result, the company cannot quickly meet the sampling needs of customers, resulting in serious loss of orders. Moreover, the scrap rate of traditional equipment is as high as 8%, and the production cost is high.
Since the introduction of the Starcard die-cutting machine, the above problems have been completely solved. The technical features of this model have played a great role in actual production. The equipment only needs 15 minutes to adjust the machine and 2 to 3 minutes to change the mold, so it can quickly respond to orders. At the same time, it also undertakes three crowdfunding orders of different sizes, with about 500 sets per batch. All debugging and mold changing work can be completed within 1 hour. The actual production time is only 4-5 hours, and the overall production efficiency is increased by more than 60%. The visual correction positioning and stepping precision feeding functions completely solve the positioning deviation problem of die-cutting quality. The position accuracy of the finished product is stable within ±0.03 mm, the edge of the card is smooth, and the scrap rate is reduced from 8% to less than 0.5%, which greatly reduces the production cost.
The Star Card die-cutting machine can process a variety of different materials, including paper, film, soft magnetic sheets, etc. Production can be completed without replacing equipment parts, only by changing settings. This completely solved the problem of outsourced production, and the on-time delivery rate reached more than 99%. The equipment’s proofing function is also quick and convenient. After the customer puts forward the proofing requirements, the debugging can be completed in 10 minutes at the fastest, and the sample can be made in 30 minutes. The success rate of sample making is as high as 99.8%, and the success rate of orders is greatly improved. Two types of finished product collection methods are conducive to the production of multi-specification orders. The function of collecting by category can save the time of manual sorting. The online post-press product packaging solution can realize the one-time completion of “die-cutting-paper collection-packaging.” The production efficiency is higher, the labor is reduced, and the labor cost is reduced by 30%.
Moreover, actual production shows that the Starcard die-cutting machine has good stability, and the average trouble-free running time exceeds 800 hours. The equipment operation interface can be switched between languages, which is convenient for foreign customers who come for inspection. The rapid technical support and parts supply from the Shenzhen headquarters ensure the timely delivery of overseas orders. The studio can now process 80 to 100 small-batch orders per month, an increase of more than 160% compared to the 30 to 40 orders per month before the equipment was added. Sales have increased by 180% year-on-year, and the overall gross profit margin has increased from 35% to more than 55%. The market competition is more intense now.
Conclusion
The Star card die-cutting machine is a step-feeding die-cutting machine mainly for small-batch and multi-batch production. Its technical design perfectly meets the flexible production needs of the printing industry, and its technological innovation solves the main problems of traditional die-cutting equipment. From the perspective of knowledge transfer, the following core data can fully prove its technical and application value and provide reliable and efficient production solutions for printing enterprises.
The Starcard die-cutting machine has some great advantages in improving efficiency: the time for changing the single-machine adjustment is less than 15 minutes, which is more than 70% shorter than the traditional equipment. The mold change time of the wooden lightweight mold is less than 3 minutes, which is more than 90% shorter than that of the traditional metal mold. The overall production efficiency is 60% to 160% higher than that of traditional equipment, and the order volume of small printing enterprises can be increased by more than 160%. The proofing response time is less than 30 minutes, the proofing success rate is more than 99.8%, and the order is more competitive. The global market trend for lightweight die-cutting tools, as well as the growing demand for efficient and flexible die-cutting equipment, means that the market will continue to grow. The CAGR of 4.1% from 2024 to 2031 means that the market has great potential.
The equipment has excellent precision and stability in terms of die-cutting quality. It has a visual correction and positioning system for the layout and a stepping precision feeding design. The position accuracy of the finished product is ≤±0.03 mm, which meets the accuracy requirements of high-end limited edition cards abroad (≤±0.05 mm). The die-cut finished products have no burrs or scratches, and there is no need to punch nail holes or connection points. The pass rate of finished products is ≥99.5%, which is 7.5 percentage points higher than that of traditional equipment (pass rate of about 92%). The 7.5 kW servo stamping power system ensures the uniformity of the stamping force and further ensures the stability of the die-cutting quality. It can die-cut various materials such as paper, film, and soft magnetic sheets.
The equipment is very flexible and cost-effective. It can produce a variety of cards, such as smart cards, business cards, game cards, playing cards, animation cards, bank cards, star cards, etc., as well as small packaging boxes. It can feed materials accurately, collect materials automatically, and discharge waste automatically. Two finished product collection methods and online back-end packaging solutions make the application more flexible. The cost of wooden lightweight molds is only one-third of that of traditional metal molds. Labor costs can be reduced by 30%, the scrap rate is less than 0.5%, and the overall gross profit margin of small printing enterprises can be increased by more than 20 percentage points. These are all very large economic benefits.
The Starcard die-cutting machine is manufactured and developed in Shenzhen, China, with the goal of adapting to different markets around the world. The equipment is very stable (it can run for at least 800 hours without failure), the operation interface can switch languages, it meets international energy-saving standards, and it meets the needs of customers in Europe, the United States, Japan, South Korea, and other places. The on-time delivery rate can be increased to more than 99%, which helps printing companies expand their overseas business.
The Star Card die-cutting machine will become the most important equipment for the printing industry to adapt to market changes and seize the market share of foreign countries. This is because it has the core advantages of being “short, flat, and fast” and can be optimized in all aspects of technology. By understanding the core technical characteristics and usage methods of digital printing, printing companies can make full use of its advantages, such as high efficiency, precision, and ease of use, which can improve production efficiency, reduce production costs, ensure product quality, quickly respond to the personalized needs of the global overseas market, and achieve sustainable development.