Rotary die cutting is a high-speed manufacturing process that uses a cylindrical die to cut, perforate, or crease rolled material as it moves continuously through the system. Unlike flatbed die cutting, which involves a stationary die pressing down on material, rotary die cutting allows for uninterrupted cutting, making it the preferred method for high-volume production runs.
Since the die is mounted on a rotating cylinder, it applies even pressure across the entire material width, reducing the risk of inconsistencies or defects. This makes it especially useful for applications requiring complex shapes, fine details, or high repeatability. Additionally, rotary die cutting can be combined with in-line automation features, such as lamination, slitting, and waste removal, further enhancing its efficiency.
Step-by-Step Rotary Die Cutting Process
The rotary die cutting process consists of several key stages that ensure precision and efficiency. Each step plays a critical role in achieving high-quality results when performed by experts.
Step #1: Material Feeding & Web Alignment |
Material, often in roll form, is continuously fed into the machine. Proper web tension and alignment are critical to maintaining accuracy, ensuring that the material does not shift during cutting. Sensors and automated guides help keep the material precisely positioned throughout the process. |
Step #2: Cutting Process |
As the material passes through the rotary die station, a rotating die applies pressure to create cuts, perforations, or creases. Depending on the project requirements, the machine may perform one of several cutting methods:Through-Cutting (Full Die Cutting): Cuts completely through the material.Kiss-Cutting: Partially cuts through adhesive layers while leaving the backing intact.Perforation: Creates a series of small cuts for easy separation.Scoring & Creasing: Partially cuts or compresses material for easy folding. |
Step #3: Waste Removal & Material Handling |
Any excess material, such as scrap or matrix waste, is automatically removed from the web. Inline vacuum systems, rewind spools, or mechanical stripping devices ensure a clean final product with minimal manual handling. |
Step #4: Rewinding, Stacking, or Sheeting |
Once cut, the finished components are collected in a format that best suits the end-user’s needs. They may be rewound into rolls, stacked in individual sheets, or prepared for direct insertion into automated assembly lines. |
Step #5: Inline Quality Inspection |
Advanced rotary die cutting systems include vision inspection and sensor-based quality control measures to detect defects in real time. These automated checks help ensure tight tolerances and consistent results, reducing waste and improving production efficiency. |
How Rotary Differs from Flatbed Die Cutting
Rotary die cutting is best suited for high-speed, continuous production of thin materials, while flatbed die cutting is more effective for thicker materials and lower-volume jobs. The difference in tooling also affects costs: rotary dies typically have higher upfront costs but lower per-unit expenses for large runs.
Feature | Rotary Die Cutting | Flatbed Die Cutting |
Speed | High (continuous operation) | Moderate (press-based cycle) |
Best for | High-volume production | Low-to-medium volume runs |
Material Thickness | Thin, flexible materials | Thick, rigid materials |
Precision | Excellent for intricate cuts | Higher for deep cuts |
Tooling Cost | Higher upfront, lower per unit | Lower upfront, higher per unit |
By using rotary die cutting, manufacturers can achieve greater speed and efficiency, especially when outsourcing to a supplier with specialized experience in handling complex, high-volume projects.
Materials Best Suited for Rotary Die Cutting
Rotary die cutting is highly versatile, capable of processing a wide range of materials. However, the material type and thickness impact the cutting method, die selection and achievable tolerances. Below are the most commonly used materials in rotary die cutting and their best use cases.
Rotary Die Cutting Material Capabilities
Material | Typical Thickness Range | Best Cutting Methods | Common Applications | Challenges |
Plastic Films (PET, PP) | 0.002″ – 0.01″ | Kiss-cut, full-cut, perforation | Medical films, labels, RFID tags | Can warp under heat |
Adhesive Tapes | 0.002″ – 0.05″ | Kiss-cut, perforation, slitting | Automotive gaskets, electronics | Sticky residue on dies |
Foam & Gaskets | 0.01″ – 0.25″ | Full-cut, scoring, kiss-cut | Insulation, cushioning, sealing | Compression affects accuracy |
Paper & Cardstock | 0.001″ – 0.005″ | Creasing, perforation, scoring | Packaging, labels, cards | Paper dust buildup |
Metal Foils (Al, Cu) | 0.0005″ – 0.01″ | Full-depth cut, perforation | EMI shielding, decorative trims | Prone to burrs and wrinkles |
Laminates & Multi-Layer | 0.002″ – 0.05″ | Multi-stage rotary cutting | Flexible circuits, medical devices | Alignment precision required |
Key Considerations for Material Selection
- Material Thickness: Thinner materials work well with kiss-cutting and intricate designs, while thicker materials require full-depth cutting or scoring.
- Adhesive Strength: High-tack adhesives can leave residue on dies, requiring specialized coatings or non-stick treatments.
- Material Memory & Flexibility: Flexible materials like films and foams may deform under pressure, requiring careful tension control.
- Cutting Precision Needs: Industries like medical and aerospace require extremely tight tolerances, necessitating laser-engraved rotary dies.
Advantages of Rotary Die Cutting for Industrial Applications
High-Speed & High-Volume Production
Rotary die cutting operates on a continuous web system, making it significantly faster than flatbed or laser cutting. Its efficiency allows manufacturers to scale production without slowing down assembly lines.
Precision & Consistency at Scale
This process ensures tight tolerances and repeatability, making it ideal for industries requiring consistent, high-quality components.
Cost-Effectiveness for Large Orders
Though rotary die cutting has higher upfront tooling costs, its ability to produce high volumes efficiently reduces per-unit expenses.
Versatility Across Materials & Applications
Rotary die cutting handles various materials, including adhesives, foams, and thin metals, making it suitable for multiple industries. Specialized techniques include multi-layer laminating, kiss-cutting, and perforating.
Automation & Seamless Supply Chain Integration
Automated rotary die cutting includes inline quality control, automated web handling, and precision cutting. Die-cut components can be completed in formats optimized for automated assembly, reducing inventory costs and ensuring just-in-time delivery without disrupting supply chains.
Customization & Rapid Prototyping
Rotary die cutting supports both large-scale production and prototyping. Quick die modifications allow manufacturers to refine designs without expensive retooling.
Learn More About Your Rotary Die Cutting Options with Colvin-Friedman
Colvin-Friedman has been die-cutting components to exacting tolerances since the dawn of the electronics age. In the decades since, we have kept up with the latest trends in materials and how they affect machine operation, ensuring the highest possible quality for our clients on runs of thousands or millions.
If you would like to learn more about how rotary die-cut components can positively impact your supply chain, contact us today. If you have a specific part in mind, you can use our handy quote form. If you are looking to discuss options more broadly, contact C-F Vice President Josh Rodman at (707) 769-4488.