R & D Proof of Concept
Rotary System Solutions: Engineering, Build, & Testing
At Bernal, we’re dedicated to cultivating our truly world-class R&D Proof of Concept program. We provide rotary system solutions that include developmental and proof of principle engineering, build, and testing. We’ve proven ourselves time and again as leaders in the field, providing concepts and testing of unique die cutting, converting, and assembly processes by developing innovative equipment and tooling configurations.
The wealth of experience we’ve gained over the decades positions us to quickly and effectively combine innovations and solutions from our various successful projects with the specific needs of the project at hand. Frequently the end result of our work is patentable and offers our customers long-term innovation and competitive advantages in their markets. We also offer a wide array of proven, turn-key systems that we’ll customize to a greater or lesser extent depending on your singular needs and goals.
New and unique products are some of our favorites to work with, as these items require innovative solutions in order to be produced cost-effectively. Bernal’s lengthy experience in this arena allows us to draw upon concepts and solutions from across many industries. Our broad knowledge base allows us to provide you with entirely new systems never before thought possible, giving you a competitive edge. We’ve done this very thing for Fortune 500 companies, startups, and we’d love to do this with you, too!


We are successful precisely because of our aptitude for increasing speed, decreasing complexity, simplifying processes and adding the capability to existing equipment. Where possible we develop non stop continuous motion workflows to replace inefficient start/stop indexing equipment greatly improving production output. Bernal has all of the technology, insight, and experience needed to serve as your R&D department, and we’re happy to put our creativity and proven record of success to work for you.
Customer Testimonials
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“For more than 10 years GMV Tool and Die has delivered more than 150 die sets from Bernal to Scandinavian customers. Most of the dies have been manufactured with Bernal’s unique laser cladding technology. Our customers have experienced outstanding results. We have had the best response possible from our customers. They come back for more.”
GMV Tool and Die
"Cavanagh Company and Bernal have been great partners for over 35 years. We at Cavanagh have enjoyed the high level of manufacturing and service that Bernal continues to deliver on. Our critical specifications and geometry are unique and have evolved over the years that Bernal has mastered in complete confidence."
Cavanagh Company
"Bernal's expertise and skill are evident in their design and workmanship. The high level of knowledge and friendly service makes Bernal an easy choice for OEM equipment."
Cascade Designs
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Blog
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.
Features and Benefits of Bernal Die Modules
Bernal Die Modules Offer Unmatched Precision Bernal Die Modules are designed to maximize die performance. As a premier die manufacturer, we know the qualities required in every module design to assure precision die cutting with trouble-free operation....
read moreCASE STUDY: STRIPPING COMB WEAR
Modified comb blocks add a blast of air directly at the problem area to help keep the combs clear of scrap. Pin Seal added to keep paper from building up around stripping pins. CHALLENGE Bernal has a customer that supplies folding cartons to a fortune 50 company and...
read moreCASE STUDY: DIE SEGMENTATION
CHALLENGE A large international customer’s project had two separate parts they wanted to produce for an application, however, one product had different interior features. Upping the scale was that these products were going to be in time sensitive production that...
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