How the Die Cutter Works
The Insignia was designed with versatility & production in mind. Everything built into the machine was engineered with the ability to adjust for an absolutely huge range of stocks or materials to be handled, anything from a 50LB cover weight stock to a 30pt laminated materials and anything in between can be fed, registered and cut on an Insignia machine in an unlimited number of shapes!
Utilizing a self-contained top suction air feed design, the Insignia is capable of feeding materials anywhere from 0.0025"-0.030" thick (0.063mm - 0.76mm)*. The feeder is governed purely via mechanical timing, so the phasing of the sheets feeding into the cutting station are ensured to remain accurate and consistent. This enables the Insignia to run materials printed pure black, with reflective or transparent properties, or with specialty finishes such as foil or raised UV inks.
The rotation of the sucker heads in the feeder of the machine are mechanically linked to the rotation of the cutting cylinders to ensure correct timing of the sheets entering the cylinder section for every sheet.
Each Insignia machine utilizes a mill-skid style feeder capable of accepting between 38-45" / 97-114cm of material in a single load. Designed to feed off a skid or pallet, the feeder can be lowered to the floor and loaded manually or via a pallet jack.
How the Insignia machine maintains phasing/timing
All Insignia machines rely on and are governed via mechanical timing rather than electronic or optic controls. Because of this mechanical timing, Insignia machines do not struggle with any type of clear, reflective or matte black materials being ran through the machine, and are also able to be serviced by many service technicians not necessarily familiar with the Insignia machines themselves.
Gearing, chain linking, cam following and spring tensioners are the governing devices for the timing within the Insignia machines, all relying on pure mechanical movements and mechanisms. There are no servo motors to go down or optic eyes to fail requiring an electrical engineer to trouble-shoot. An Insignia machine can be serviced via an auto mechanic if necessary.
Magnetic Cylinder Configurations
The Insignia machines are offered in two varying magnetic cylinder configurations. The machines can be supplied with a magnetic upper cylinder and a solid, hardened anvil cylinder on bottom OR with a paired set of magnetic cylinders.
The single magnetic (1M) configuration is primarily designed for a user that is looking to cut a large variety of products on the machine such as shaped greeting cards, door hangers, decals, display signs, garment tags and other flat products. This configuration lends itself to short run work as the changeover required is under 5-10 minutes.
The dual magnetic (2M) configuration was developed for the carton or pocket folder producer, as well as for users looking to become producers of boxes & packaging products. This system uses what is referred to as a paired set or 'male/female' set of dies; one on upper cylinder and the other on the lower cylinder.
This allows for the ability to channel score on either or both sides of the substrate at the same time, as well as emboss or deboss.
The 1M configuration utilizes the hardened anvil lower cylinder as the cutting surface.
A 2M machine will always run a paired or male/female set of die tools on both upper & lower cylinders. The Insignia can be configured single magnetic in a bearer or non-bearer system. A dual magnetic machine is always supplied in a bearer configuration for two reasons; the die plates mount via a pin system & require a high level of precision in order to match up correctly, and second to prevent the possibility of an operator accidentally damaging the die set.
Single magnetic cylinder configuration shown w/ a solid anvil lower cylinder. This system would accept a single die tool and is ideal when running multi-level dies involving die cutting and kiss cutting.
Dual magnetic cylinder configuration shown w/ paired set of magnetic cylinders. This system would accept a paired set of die tools and would be capable of creating scores, embosses or kiss cuts from both sides of the substrate in a single pass.