What does die-cutting mean?

The term "die-cutting" stands for processes in which film parts are separated from the surrounding material under pressure. Die-cutting is a very complex process that requires expert knowledge and the result can be influenced by various factors.

What techniques and die-cutting processes are there?

In general, the following die-cutting techniques are used, depending on the type of film:

• conventional flatbed or stroke die-cutting 
• rotary die-cutting. 

Both techniques can be used to die-cut film.

Flatbed die-cutting

Flatbed punching machines press a flat punching tool from above onto the material to be punched. A lifting die-cutting device consists of a press in which a die-cutting tool is fixed. This consists of an upper tool with punches and a lower tool with a matching die. Both tools are precisely aligned with each other so that the punches mounted in the upper tool hit the die of the lower tool. The upper and lower tools move parallel to each other via guides.  The punchable film runs between the tools. When all punches are plunged into the dies, the entire punching force acts on the material to be processed at once. The machines, also known as stroke die-cutters, offer the advantage that die-cutting plates in common formats are available at low cost. In addition, the tools are easier to change, making the process particularly suitable for frequently changing batches.

Rotary die-cutting

In this process, the film is fed into the die-cutting machine in rolls. It is threaded onto the machine so that the impression cylinder can pull it past the magnetic cylinder. Its cutting edges punch the material to or from the desired depth. The film die-cuts are then separated from the waste.

The use of rotating systems offers the following advantages:

• high production speed,
• higher degree of precision compared to flatbed machines,
• possibility of performing several functions simultaneously (e.g. perforating, printing, laminating).

What needs to be considered when die-cutting films?

Optimum results can only be achieved with both processes if the die-cutting process is precisely aligned to the respective starting material. The film thickness plays just as important a role as the plastic and the properties of the punchable film. 

The gap dimension, which defines the distance between the die-cutting tool and the impression cylinder, is also important. If it is too small, the entire raw material may be punched through, even though only one punch was desired. If it is too large, the tool does not go deep enough. 

Another success factor for good punching results is the use of precision punching parts.

Advantages of the die-cutting process 

Die-cutting of plastic films offers numerous advantages:

•  high precision during production.
• no thermal material change.
• effective mass production with short cycle times.
• low unit costs due to automation.
• great variety in terms of shape and material used.

However, this usually only applies to long runs, while the stamping process is not the right form of processing for small quantities.

What kind of plastic are films for diecutting made of?

In our portfolio you will find different types of high-performance films made of the following plastics:

Polycarbonate films

Polycarbonate films are highly impact resistant and optimally printable. Further advantages are a high dielectric strength, their temperature resistance, a high dimensional stability and optical transparency. Thanks to a protective film, polished - and thus very sensitive - surfaces are protected before and during processing. High-performance PC films are often used for stable and high-quality die-cut parts such as labels.

PMMA films

PMMA film is particularly UV and weather resistant. Plexiglas films impress with their special light transmission properties as well as their absolute transparency and colourlessness. Another advantage is that it can be cut easily on laser equipment. PMMA die-cuts are suitable for outdoor applications such as labels or front panels.

Polyester films

Biaxially oriented polyester film (BO-PET) is characterised by a high resistance to high temperatures. They also have good tensile strength, excellent chemical, mechanical and thermal stability and excellent transparency. Polyester films are good electrical insulators, show low moisture absorption (0.3%) and high dielectric strength.

High-performance films

By this we mean innovative, punchable films with special properties such as:

• Particularly high temperature stability.
• Resistance to scratches.
• Resistance to chemicals.
• Weather resistance for outdoor applications.

Sustainable films

In today's world, sustainable, more ecological film solutions are becoming more important and popular. The König Film Centre is currently building up a range of sustainable, bio-based film products. Less fossil raw materials are required for production, so the use of these films results in a lower CO2 footprint.

Depending on the application, a different die-cutting film is recommended. We will be happy to advise you on the choice of material and recommend the right die-cutting foil for your application. In our range you will find a wide selection of colours, surfaces, thicknesses and materials for almost any application. We stock our products in rolls, in various lengths and widths or directly cut to your desired dimensions.

Do you already know about our REVINK film recycling programme? This recycling programme ensures that rests of technical films are collected from you and go into the recycling process to close the loop.

What are typical areas of application for punchable films?

Die-cut films play an important role in many applications. Among them are applications as:

• Front films: housings, apparatus or devices are often protected or provided with a front film with individual printing. 
• Closure labels: In order to close boxes, bags or crates reliably and easily, one-sided adhesive moulded parts or labels are used. 
• Insulation die-cut parts: Die-cut parts made of insulation films are used in many electrical engineering and electronics products. 
• Protective films: Many surfaces need to be protected during transport or use. They should not be scratched, chemically damaged or given an additional property (for example, good gliding).
• Lighting, LED and sensor technology: long-lasting and economical LEDs have become established for lighting applications. However, in order to move from point light sources to a well spread illumination, moulded parts made of diffusely scattering plastic films are used extensively. 
• Seals: Containers, housings or entire control cabinets are sealed with suitable materials so that nothing can get out or anything can get in. For this purpose, suitable plastics are punched into the appropriate shape. 

If you have any further questions about our punched foils or the manufacturers, please do not hesitate to contact us. We look forward to your enquiry!

In which thicknesses are the die-cutting films available?

We offer our technical foils in material thicknesses from 0.1 mm to 1 mm. From 100 µm to 500 µm, the material is available in rolls or cut to size into sheets. For thicknesses of 750 µm and 1 mm we only offer formats. We offer special films from renowned manufacturers and leading brands in various colours, thicknesses and surfaces. Depending on the material and film type, the thickness and surface of the film differ. You can find more information about our product range at www.folien-zentrum.com.

Depending on the application, a particularly thin film or a stable film with a greater thickness is recommended or required.

Service, converting and delivery time.

As a wholesaler, we can supply you with films for die-cutting as rolls in various widths and lengths, starting from small quantities. Even right-angled sheets in your desired format are no problem for us. Just ask us for the required format and we will make you a suitable offer. We will also be happy to answer any further questions you may have on the subject of ordering, storage, packaging and delivery. On request, we can recommend a suitable die-cutting company for your needs.

If you have any further questions or requests, please do not hesitate to contact us. We can advise you on the right plastic film for your project, thicknesses, formats, dimensions and prices. Please contact us if you need samples or a concrete offer. You can order films for die-cutting from us by phone, e-mail or online. The team of the König Film Centre is looking forward to your enquiry or order!