Reduced costs, minimized downtime, and improved accuracy—with laser die cutting, you get all three.
Laser cutting has quickly become recognized as a more accurate, flexible solution that outperforms traditional die cutting methods in several ways. This non-contact process eliminates the need for hard tooling and is a fast, clean, cost-effective production solution which maintains an exceptional standard of quality. Laser cutting is especially ideal for applications with feature locations, tolerances, size, or material characteristics that would typically be difficult or impossible to process using a traditional die.
By eliminating tooling, laser die cutting can reduce costs and improve accuracy
. Because laser cutting is an entirely digital process, pattern changes are simple, requiring only edits to drawing files without any downtime for setup or die creation. Other advantages include:
- Unlimited cutting paths
- Non-contact processing
- Fast changeover and process on-the-fly
- No tool wear or consumables
- Increased accuracy with the ability to hold tighter tolerances
- Suitable for both roll and sheet-fed materials
- Capable of achieving more intricate, complex designs
- Lead times, costs, and storage associated with dies are eliminated
- Process difficult to convert materials, such as abrasives and adhesives, with ease
- Design changes can be made quickly without lengthening timelines
Laser cutting has virtually unlimited applications and can be used to process a wide variety of papers, plastics, textiles, and thin metals.
Laser Cutting Applications:
Laser Cutting Graphic Arts
- Borders of folding cartons
- Decorative designs in greeting cards, stationery, business cards, promotional materials, and more
- Boarders of point-of-purchase displays or retail signage
- Perimeters of sticker/label sheets, combined with the laser kiss-cutting process
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Laser Cutting Electronic & Industrial Components
Laser Cutting Medical Components
- Medical component subassemblies from source material
- Flow channels for multilayer microfluidic platforms
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Laser Cutting Flexible Packaging
Small and Large Volume Laser Cutting Production
Creating dies can be costly and time consuming so when it comes to low volume or personalized jobs laser cutting is often a more efficient and cost-effective solution. As opposed to using a metal die, laser cutting only requires a vectorized digital file. Working from a digital file not only reduces the cost and storage issues associated with metal dies, but it also makes the design production-ready instantly as there is no need to wait for a die to be created. These circumstances make laser cutting a practical option for low quantity production.
When reviewing higher quantities, laser cutting has an advantage over die cutting in terms of pattern complexity and variable data processing. In most cases, laser cutting would not be a cost-effective alternative to die cutting for high volume production of one basic shape or pattern. However, if the design involves extensive and complex detail, or tolerances that are unattainable with metal dies, then laser cutting is more ideal for high volume production applications. Additionally, because of our digital technology, LaserSharp® laser cutting systems can process variable data on-the-fly, making high volume runs of variable patterns simple and fast.
Laser Cutting Digital Flexibility
Die production and storage is time consuming and costly. And once a die is created, the design is static and revisions require downtime to create new dies. In contrast, because the laser converting process is completely digital and utilizes vector files to guide the processing of the laser, pattern changes are simple and only require edits to drawing files, decreasing system downtime. Laser cutting can also be combined with other laser processes such as perforating, scoring, kiss-cutting, etching, and ablating, resulting in finished pieces in less time. Production speed is dependent on material composition, laser source, and die line length.
Easier to Convert Difficult Materials
Because our LaserSharp® technology is a non-contact processing method, difficult to convert materials such as abrasives and adhesives are processed more accurately without the drawbacks associated with conventional tooling. The laser converting process is able to control adhesive flow and build-up, resulting in increased part quality. Adhesive layers are cut at controlled depths and the downtime associated with cleaning adhesive buildup is eliminated. Additionally, abrasive materials are often problematic to process because they quickly dull metal dies which consequently need to be replaced often. Conversely, our low maintenance laser systems do not require consumables and eliminate the issue of tool wear.