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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 24pt card stock and anything in between can be fed, registered and cut on an Insignia machine. 


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Starting at the Feeder

      Utilizing a self-contained top suction air feed design, the Insignia is capable of feeding materials anywhere from 0.0025"-0.025" thick (0.063mm - 0.63mm)*. With a self-contained Becker air pump, both the volume of blow as well as amount of suction can be individually adjusted to accommodate for varying materials. Each individual sucker head is adjustable laterally on the machine, as well as vertically if needed. The feeder is governed purely by mechanical timing, so the phasing of this section is ensured to correlate with the rotation of the cylinders. 

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How Each Sheet is Registered

      Once sheets are picked up via the sucker heads, they feed the sheet in under the two grey drop wheels above. Because the Insignia machine is purely mechanically functioning, the timing of the machines are ensured to stay consistent. Once the grey drop wheels begin their movement, the sheet is now fed into the machine and runs under a double-sheet detector that functions on proximity, not optics. Within 30 seconds it can be set to any caliper of material, including coated, laminated, spot UV or uneven surfaces. 

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      After being fed, the sheets will enter the register section of the Insignia machines. Each Insignia machine registers sheets in a similar fashion to an offset-press, utilizing a guide & grip system. Referring to the above image; #1 depicts the front "head stops" of the machine. These stops are on an eccentric movement, and are capable of moving the total cut "north/south" or up and down on the sheet, or could also be used in influencing an angle to the sheet, or to counter-skew to match any print error. #2 is the side pull guide of the register system, and #3 is the micro-adjustment of the side pull guide. The gold pin on the right side of the pull guide is what each sheet is pulled up against. The micro-adjustment moves the side guide block 1/128th of an inch with each click for fine tuning of the registration. 

      The side pull guide can pull to either the left or the right with a 2 minute change on the machine, or for Insignia7 machines a second "B Guide" is available as well if the machines are finishing work off of more than one printing press. 

      The black thumb screw on top of the #2 side pull guide is a pressure adjustment to account for changing thickness in materials being ran. The guide is able to be de-tensioned to compensate for very light weight materials to ensure no buckling for a consistent register, inversely it can be tightened down for a positive pull on thicker substrates such as laminates & plastics. 

      The last step in the register process (not pictured) is a set of gripper fingers housed in the lower cylinder that come around and grab the leading edge of each sheet & pull it through the cylinder section, so each sheet is 100% controlled during the cutting process. The gripper margin on any Insignia machine is 0.5" or 12.7mm, and the shortest leading edge currently available on a flexible die is 1/16" or 0.0625" or 1.5875mm. This means that the soonest any cut can occur down from the leading edge on an Insignia machine is 0.5625" or 14.2875mm.  


How The Cutting Occurs

       The cutting takes places between the upper and lower cylinder. Depending on if the machine is single or dual magnetic the material is either cutting against the lower anvil cylinder or a lower flexible die. The outer metal rings on the edges of the cylinder pictured above create a fixed gap between the cylinder, referred to as bearers. These ensure the die tools cannot get damaged as well as ensure constant cutting depth across the cylinder. This serves to also eliminate the possibility of an operator damaging a die tool. 

     Dual magnetic cylinders on an Insignia7 machine. The upper die contains the cutting blades and the scoring rule, the lower die contains the cutting surfaces as well as the scoring channels. The dies can be mounted on either upper or lower cylinder to achieve a score from either direction when running       in-line with a folder/gluer unit. 

     Dual magnetic cylinders on an Insignia7 machine. The upper die contains the cutting blades and the scoring rule, the lower die contains the cutting surfaces as well as the scoring channels. The dies can be mounted on either upper or lower cylinder to achieve a score from either direction when running       in-line with a folder/gluer unit. 


Delivery Systems

Stripping Unit

     If the Stripping Unit delivery is being utilized, the sheets after being cut are delivered out from the cylinders onto a vacuum table that transports the sheets through a series of trim deflectors that divert the skeleton or waste portion of the sheet downward into a waste bin. The individual die cut pieces are grabbed and transported through an additional transport section capable of spreading streams of product depending on size of pieces being ran. From end of this section the pieces are either delivered onto a shingle conveyor for collection or run directly in-line into a Folder/Gluer for packaging, presentation folder, or greeting card production. 

     If the Stripping Unit delivery is being utilized, the sheets after being cut are delivered out from the cylinders onto a vacuum table that transports the sheets through a series of trim deflectors that divert the skeleton or waste portion of the sheet downward into a waste bin. The individual die cut pieces are grabbed and transported through an additional transport section capable of spreading streams of product depending on size of pieces being ran. From end of this section the pieces are either delivered onto a shingle conveyor for collection or run directly in-line into a Folder/Gluer for packaging, presentation folder, or greeting card production. 

      Above is an illustration of a sheet as it moves through the stripping unit after being die cut. 

      Above is an illustration of a sheet as it moves through the stripping unit after being die cut. 

     Above is a deflector finger of the stripping unit. These deflector fingers serve to divert the skeleton of the sheet downward into a waste bin while allowing the cut pieces to continue on. Deflectors can be as thin as 0.010" wide for use with 1/8" bleeds. 

     Above is a deflector finger of the stripping unit. These deflector fingers serve to divert the skeleton of the sheet downward into a waste bin while allowing the cut pieces to continue on. Deflectors can be as thin as 0.010" wide for use with 1/8" bleeds. 

Receding Stacker

     If the Receding Stacker is being utilized, the sheets are delivered onto a platform as a complete sheet. This delivery system is commonly utilized to deliver either sheets of kiss cut decals/stickers/labels, or very small products unable to be removed in the stripping unit. Pieces would be held into sheets via tick marks. Stacker delivers onto wheeled cart, so when run is complete cart can be wheeled away & another installed for further production. 

     If the Receding Stacker is being utilized, the sheets are delivered onto a platform as a complete sheet. This delivery system is commonly utilized to deliver either sheets of kiss cut decals/stickers/labels, or very small products unable to be removed in the stripping unit. Pieces would be held into sheets via tick marks. Stacker delivers onto wheeled cart, so when run is complete cart can be wheeled away & another installed for further production. 

     The stripping unit and receding stacker delivery systems can be interchanged for one another in five minutes or less. The Insignia machine is sold standard with the waste stripping unit, if the receding stacker is desired please inquire. An in-line Folding/Gluing option is also available direct with the Insignia for packaging production.