3.jpg

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! 


Feeder

       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. 

Feeding1.gif

       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.  

Feeder2.gif

       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.


Registration

 Left-hand pull register on Insignia machines. Head stops are stopping lead edge of sheet, side guide is pulling sheets to a register pin & gripper fingers are grabbing & pulling each sheet through the cutting cylinders. Insignia machines are capable of registering to both left and right hand sides of a sheet. 

Left-hand pull register on Insignia machines. Head stops are stopping lead edge of sheet, side guide is pulling sheets to a register pin & gripper fingers are grabbing & pulling each sheet through the cutting cylinders. Insignia machines are capable of registering to both left and right hand sides of a sheet. 

 Shown above pulling sheets to the left hand side, Insignia machines are capable of registering to the left or right hand side of the sheet.

Shown above pulling sheets to the left hand side, Insignia machines are capable of registering to the left or right hand side of the sheet.

 Slow motion of the gripper finger system housed in the lower cylinder of all Insignia machines grabbing the leading edge of each sheet as it is pulled through the cutting station. This allows for maximum control of the material as it is being die cut. 

Slow motion of the gripper finger system housed in the lower cylinder of all Insignia machines grabbing the leading edge of each sheet as it is pulled through the cutting station. This allows for maximum control of the material as it is being die cut. 


How the Insignia machine maintains phasing/timing

Mechanical timing GIF.gif

       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. 

Mechanical timing 2 GIF.gif

       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. 

Cylinder illustrations.jpg

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 configuration                                                 Dual Magnetic configuration

                   Single Magnetic configuration                                               Dual Magnetic configuration

      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.