Thursday, March 2, 2017

Die cutting with a transparent die cutting tool

The Paperfox KB-32 die cutter is a really versatile device, you can crease, die cut and punch with it.
With some modification as in the picture bellow you can die cut even 9x12cm products.


The modifications:

  • 2 pcs 10x14cm steel plate mounted into the device
  • The M8 screws at the right side of the picture are changed for longer ones
  • The spring and the pressing bar also should be changed
  • We equipped the device with a setting screw (left side of the picture) to limit the pressing force
With this setting screw you can limit the cutting force

The mayor davantage of the transparent die cutting tool, that you can adjust the cutting lines to the printed elements. 



Place a cutting plate under the sheet to be cut, put the tool on the sheet and position the tool to the printed elements. Place all together into the die cutter and cut it.



There are no ejecting rubbers in the tool so you can see the printed elements well. There is a hole on the tool so you can remove the cutted paper manually from the tool.


Saturday, February 18, 2017

What kind of double sided adhesive tape can be used in Paperfox tape applicators?

The Paperfox TD-1 tape applicator head is an affordable device for placing double coated pressure sensitive adhesive tape on paper cardboard plastic foil or other sheet materials but the usage of this useful device has some limits.

Paperfox FTD-1 tape applicator
The most obvious limit is  the width of the tape. We are manufacturing this heads for 12 and 20mm maximal tape widths.

The other limit is the material of the tape. 

To understand this limit let's have a look at to the construction of the double coated pressure sensitive adhesive tapes.

The construction of the double coated pressure sensitive adhesive tapes.

Double sided adhesive tape












Release liner

The white paper strip on the photo is the release liner. Release liners are usually paper coated on booth sides with silicone layer.
The width of the liner is usually the same as the width of the adhesive coated carrier, but the so called "finger lift" tapes having extended liners to make the manual removal of the release liner easier.

Paperfox tape applicators can applicate tapes only with easy to tear thin paper release liners. (Fortunately the most release liner is easy to tear)

Backing or carrier

The transparent strip is the backing or carrier coated on booth sides with adhesive layer. The carrier can be different:

  • acrylic film
  • other plastic film
  • felt or non-woven tape
  • paper
  • foam materials
  • etc...
Paperfox tape applicators can applicate tapes only with easy to tear carrier such as paper, felt or non-woven tape.

Adhesive

There are different adhesives used. Rubber based adhesives are having a high initial strength so they sticking to the paper quickly providing a stabile workflow. Unfortunately if you keep this kind of tapes long on stock it loses the quality don't sticks well the tape application can be unstable.

Acrylic adhesives having weaker initial strength but the quality is more stabile and having better environmental (temperature, chemical...) resistance. 

Tear test

The easiest way to determine if the tape can be used in Paperfox TD-1 Tape applicator is to test. Try to tear the tape.


Double sided pressure sensitive adhesive tape

Breaks easily as the white tape on the photo, then it can be used. If the backing material is stretches and hard to tear then maybe that the tape applicator head can't cut the tape well.

If the tape is old and there are gaps between the turns then the glue maybe dry and don't sticks to the paper well. In this case the tape application can be stopped. 

What if the tape sticks "too good", and it sticks to the guiding elements of the tape applicator?

In this case you can put a drum sanding cylinder on the guiding screw as in the picture below.

Paperfox TD-1 tape applicator






Wednesday, January 11, 2017

Why slippage occurs in cylinder die cutters?

Flatbed die cutter cut the full size of the sheet simultaneously. The cylinder of the cylinder die cutters roll above the material to be cut and the cutting made under the cylinder.



1. Die board
2. Steel rule die
3. Cylinder
4. Material to be cut
5. Section under cutting



Unfortunately, the cutting happens not at one point, but beside the cylinder a few millimeters.
Consequently the cutting force (F) is not perpedicular to the surface there is a longitudinal component (F2) as well. This force causes the longitudinal sliding effect of the sheet to be cut in cylinder die cutters.

This sliding effect and inaccuracy depend on

  • the thickness of the material to be cut
  • the material of the sheet to be cut
  • the diameter of the cylinder
  • the angle of the tool and cylinder
  • a lot of other circumstances

Monday, December 5, 2016

Why the tool should be placed angled in the cylinder die cutter?

Flatbed die cutting machines cutting the whole sheet at the same time. It needs a big force so flatbed die cutters are big, robust and certainly expensive devices. Cylinder die cutters are different: The cylinder rolls through the sheet cutting the whole width in the same time but in longitudinal direction cuts only a small length at once.


1 - Steel rule
2 - Die base
5 - In the same time cutted area




- Cutting force chart




If the die cutting tool has long straight cutting lines ant they are positioned parallel to the cylinder then the cutting force increasing very much when the cylinder rolls upon this lines.

1 - Steel rule
2 - Die base
3 - Cylinder
4 - Meterial to cut



Do to the increased force the cylinder curving so the device can't cut the whole width in the same way.
You can reduce this effect by placing the steel rule die cutting tool angled under the die cutting cylinder.


1 - Steel rule
2 - Die base
5 - In the same time cutted area




- Cutting force chart

Sunday, October 23, 2016

What is the maximum size of the die cutting tool which can be used in the Paperfox cylinder die cutting machines?

Our customer often asked us that what is the maximal size of the tool which can be used on our cylinder die cutters. Now I'll try to explain this issue.

The grey rectangle (70x75cm) is the size of the machine table, but you can use for die cutting only the green rectangle inside because
  • There are 2-2cm in the left and right side where are the aluminium profiles so you can't place tool for this area
  • There are 15-15cm place at the begin and end of the table which are under the cylinder at end positions so you can't place tool for this area

So you can die cut with 5 degrees rotation the sizes marked on the following drawing:


If you place the tool with 10 degrees rotation then you can die cut maximum the following sizes:


There is a longer version of this device, the Paperfox H-2 rotary die cutting machine which can use maximum the following tools:


The Paperfox H-500A die cutter is a tabletop device and it can handle tools as in the following drawings:





Friday, October 7, 2016

Two tricks for the Paperfox tape applicators

1. 
If the paper curls up at the edges and it bumps to the knife it can cause paper jam and stop the machine. With a peace of plastic plate or a peace of wire as in the pictures you can avoid this problem.




2.
If the adhesive band sticks on the guiding screws it can also cause jam. Put a small (1/4") drum sanding cylinder on the guiding screws so that it can turn around and the problem is solved.


Monday, August 29, 2016

Edge protector cutter up to 100x100x8mm

The Paperfox EVV-3 Edge protector cutter is a very popular device, but it can cut cardboard edge protectros only up to 80x80x5mm.
Now we modified a Paperfox EVV-3 Edge protector cutter to cut cardboard edge protectors up to 100x100x8mm.