Crush Cut Dies
We make our crush cut rotary dies from solid tool steel, assuring an exceptional level of hardness and longevity. We manufacture these dies to exacting tolerances in order to ensure a precise cut, smooth die rotation, and consistently accurate results.
Reasons to Use Crush Cut Dies:
- Capable of extremely high-speed operation
- Machine sharpening
- Fully-hardened, solid steel construction for strength and longevity
- Dies can be partially or fully segmented
- Capable of quick-changing
- Precise cutting shape tolerances
- Scrap stripping
Sharpening Crush Cut Dies
Each crush cut die produced at Bernal is durable enough to withstand multiple sharpenings throughout its die life. Each time we sharpen a Bernal crush cut die we bring it back to the same flawless quality it had when it left our facility, keeping it as precise and consistent as the day you installed it.
Partially or Fully Segmented Rotary Dies
Our crush cut dies can feature specially designed segments and removable rings to accommodate a wide variety of applications and enable selective repair of high wear areas. In addition to cutting, these partial or fully segmented dies are also perfectly suited to embossing and laminating. The removable segments turn a generic carton die into a fully customizable solution for several end-users simply by changing customer specific segments in the die, spreading the cost justification of a single die set over multiple customers and applications.
High-precision machining techniques are essential to producing dies with exceptionally long life-spans. Our Advanced Machining Lab with a climate controlled environment ensures that your die is manufactured to the highest standards, using CAD/CAM, CNC and CMM inspection.
- Cutting edge accurate to .001″(.025mm)
- Web widths from 1″ to 110″ (50mm to 2794mm)
- Die diameters from 3″ to 40″ (76.2mm to 762.0mm)
- Run-out accurate to .0001″(.0025mm)
- Hardness: 60-62 RC
- Sharpenings: up to 5
Crush Cut Die Life Comparisons
- SBS Board 40 Mil. Revs
- Poly Board 80 Mil. Revs
- Lead 8 Mil. Revs
- PVC 5 Mil. Revs
- Sandpaper 2 Mil. Revs
- Poly Board
- Recycled Board
Flexible vs. Solid Rotary Dies. What’s the Difference?
There are two types of rotary dies: flexible and solid. Rotary die cutting involves either a flexible or solid rotary die. These dies are both cylindrical dies. A flexible die is made of a thin sheet of steel, and wraps around a magnetic cylinder. A solid die is a solid steel cylinder, and is traditionally used in more long run applications for extended die life. Bernal develops solid rotary dies for converting and product manufacturing applications throughout many industry sectors.
Bernal Rotary Die Cutting is essentially a process that can cut or form materials into virtually any shape. Technological developments have expanded the processes that a rotary die configuration can perform. Die cutting is a primary go-to process in the material...read more
Rotary die cutting is a versatile fabrication process employed in a wide array of manufacturing sectors to precisely and efficiently cut, form, and shape a wide variety of materials ranging from paper to plastic, and from metal to edible food products. Rotary dies...read more
We had the pleasure of contributing to the March 2019 issue of FLEXO Magazine, on helping open the communication for printers when specifying dies for a folding carton project. The variability of modern converting technologies has significantly increased the...read more