Improvements in the die cutting process are slicing waste from various facets of the process. Electronic transfer of design instructions reduces the opportunities for incorrectly manufactured dies. Segmented dies are allowing only the worn portions of the die to be replaced, rather than the entire piece. Since a die is a cutting tool, its edges wear. More durable materials are being used. When combined with the ability to resharpen more times, blade life is being extended.

Incremental changes are seen in the future. As die production costs decrease dies will be more cost efficient on the shorter runs which are foreseen across the printing industry.

Fundamental changes are also foreseen in the realm of cutting. Lasers are anticipated to carve out a portion of the die cutting market. Lasers offer the advantage of software reprogramming changes rather than hardware production for each new job. Current disadvantages are slower line speeds and higher costs, both of which are changing in the laser's favor.

Author: Ed Rogers
Source: FLEXO, Oct. 1999, p. 22-26