When you need a series of pieces cut from flexible materials, like gaskets, pads, or spacers, you have several processing options. Two of the more common techniques are flatbed die cutting and rotary die cutting.
Both flatbed and rotary cutters can produce great end products with an efficient process, but which one is best for your design? The following explains what die cutting is and the differences between flatbed and rotary die cutting.
The Basics of Die Cutting
Die cutting is a fabrication process that uses a shaped blade (called a die) to cut flexible materials such as foam, rubber, and plastic to make gaskets, dampeners, bumpers, and other components. With die cutting, your pieces can be cut uniquely and accurately, so each design works for your end use and each part in a series is identical to the next.
The process begins with designing the part first rather than the die. An engineer specifies the part’s dimensions, material, thickness, and tolerances. That geometry is used to create a die with the required edges, holes, and dimensions needed to reproduce the part at scale.
Because tooling can be expensive, a manufacturer may produce prototype parts to verify the design before committing to permanent dies. This lets engineers check the fit, dimensions, and performance before launching into production tooling. If the part design and specifications are already verified, prototype tooling is usually unnecessary.
After the design is finalized and the die is manufactured, it is installed into the cutting machine and production can begin.
Understanding the Types of Die Cutting
Die cutting is a broad manufacturing process with different methods for producing parts based on their material, geometry, production volume, and the level of precision required.
- Flatbed die cutting stamps out each product using a hydraulic press and steel rule dies. The raw material feeds along the base while the press is pushed down vertically to make the cut. The vertical motion allows for thicker material to be shaped and results in very little curvature of the material.
- Rotary die cutting feeds the raw material between two rolling cylinders at a very high speed. The shape is cut out on the rolling die with high tolerance and high accuracy. Rotary die cutting can cut each piece all the way through or kiss-cut, leaving a paper lining to keep every piece together until needed.
| Consideration | Flatbed Die Cutting | Rotary Die Cutting |
| How it Cuts | Vertical pressing | Continuous rotating die |
| Material Feed | Sheets, rolls, or individual pieces | Usually roll-fed |
| Suitable Material Thickness | Better suited to thicker materials | Better suited to thinner materials |
| Production Speed | Slower, as it requires a cutting stroke for each cycle | Faster, as it supports continuous cutting as material moves through the machine |
| Initial Tooling Cost | Generally lower | Generally higher |
| Production Cost (At High Volume) | Generally higher per-piece cost due to slower cycle times | Generally lower per-piece cost due to continuous operation |
| Best For | Prototypes, varied parts, and thicker materials | High-volume repeat production |
When to Choose Flatbed or Rotary Die Cutting
Choosing between rotary and flatbed die cutting usually starts with the material. The material’s thickness, flexibility, and behavior during cutting all play a role in determining the best converting method.
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We use rotary die cutting when:
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We use flatbed die cutting when:
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The right die-cutting method can also depend on production volume and tooling costs. The flatbed die-cutting process is slower, which can cost more per part. However, upfront tooling costs tend to be lower. This makes it a better choice for limited production runs or for materials unsuitable for faster production methods.
Rotary cutting dies are more expensive to manufacture upfront, which initially makes it a more expensive process. However, the speed of production ultimately makes it more cost-effective as volume increases.
Another factor that influences production cost is material waste. Because rotary dies cut from a continuous roll, part placement can often be arranged to use the material more efficiently. If a process allows you to get more usable parts from the same amount of material, it ultimately makes the cost per part lower. However, waste depends heavily on the geometry of the parts and how they must be arranged or nested to achieve the design, not just the style of the cutting equipment.
Need Custom-Fabricated Materials? Contact Us Today!
American Flexible Products is a nationwide converter of flexible materials, from foam to rubber to silicone and more. While we have a wide variety of custom converting methods, you don’t need to be an expert in choosing the best one. Our engineers help you choose not just the most optimal materials, but the best cutting method for your design, budget, and production goals.
Call 952-368-4225 or send us a message to learn more about our rotary die cutting services. Our material experts will help guide you through our process and give you a free quote.
