Bernal invented the solid hardened rotary die in the late 1960s by creating a wedge-type cutting edge on a solid cylinder through the use of EDM (electric discharge machining). Our proprietary process allows us to precisely manufacture dies, thereby achieving high-quality cuts at high speeds for countless materials and products. We make Bernal Crush Cut rotary dies from solid tool steel, assuring an exceptional level of hardness and longevity. These dies are manufactured to exacting tolerances in order to ensure a precise cut, smooth die rotation, and consistently accurate results.

Below are seven reasons to use these specific dies:

  1. Capable of extremely high-speed operation
  2. Machine sharpening
  3. Fully-hardened, solid steel construction for strength and longevity
  4. Dies can be partially or fully segmented
  5. Capable of quick-changeover
  6. Precise cutting shape tolerances
  7. Scrap stripping


Triangular shaped cutting edge on the die provides slight cutting action when initially contacting the substrate. The mechanical action of the wedge shaped blade forces the substrate to tear apart at the last portion of the cut. This can result in jagged fibers rather than a clean cut at the point of separation.

Crush Cut Die Advantages:
• Lower cost dies since bottom roll is smooth
• Easier setup
• Easier running adjustment
• Easier part stripping

Crush Cut Die Disadvantages:
• Less clean product cut edge
• Shorter wear cycles between sharpenings
• Fragile blade geometry
• Metal-to-metal contact between blade and anvil
• Fewer resharpenings (shorter die life)

To find out more about Crush Cut Dies and their key principles, please download our FREE Bernal Rotary Dies Guidebook.