Crush Cut Dies

We 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 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

Typical Materials

  • Poly Board
  • Cloth
  • Lead
  • Sandpaper
  • Polypropylene
  • Paper
  • Recycled Board
  • Dough
  • Non-woven
  • Laminates
  • Fiberglass
  • Copper

Bernal Dies can do some amazing things.



Customer Testimonials


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.

Specifying Folding Carton Dies with FLEXO Magazine

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...

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Why Bernal Is The Industry Leader In Rotary Dies and Packaging

Since 1972,  Bernal Rotary Dies has been producing Rotary Dies and Systems for the folding carton industry and have conquered many challenges conversion projects. Throughout the years, we have helped create some of most iconic and recognizable packages from french fry containers to mega-size beverage cartons.

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Vacuum Transfer

Vacuum Transfer Techniques for Rotary Die Cutting — An Overview The use of the vacuum transfer technique allows non-stop transfer of die cut parts onto another part or web while maintaining accurate relative positions.  As the material is...

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Bernal Rotary Dies

2960 Technology Drive
Rochester Hills, MI 48309


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