Thin Material Blanking Die Design & Build
A Healthcare Manufacturer's Critical Challenge
A health care manufacturer came to Die Technology based on a referral they had received while in search of a die supplier with expertise in cutting thin and ultra-thin materials. The machine design group had built an automated manufacturing line but was having difficulty with the dies within the automation system – the dies wouldn’t cut the product consistently and were causing the automation line to shut down. The die vendor could not resolve the inconsistency of the cut, so the engineering team approached Die Technology for a solution.
Our Approach: Immediate Relief, Long-Term Success
(Blanking die for extruded polymer)
After an initial consultation, the design team at Die Technology and the engineering team from the health care manufacturing company determined a two-step solution. First, Die Technology would make new cutting components for the existing dies to get the automated manufacturing line qualified and running. Secondly, Die Technology would design and build new matched metal blanking dies for reliability, longevity, and ease of maintenance.
Innovative Solutions for Longevity
Die Technology successfully rebuilt the existing dies as a short-term fix and simultaneously began a new tool design that would satisfy the long-term requirements of the product line.
The tooling needed to be redesigned due to several customer requirements. First, the automated production line needed to produce 30 assemblies per minute and maintain 23 hours of uptime per day. In addition, the customer required the tooling to sustain a minimum of one million cycles before sharpening. The dies also needed to fit into the space allocated in the existing machine design and interface with the existing drive mechanism. Another requirement was that the dies module needed to have the ability to be quick changed into the automation line in under 15 minutes. Finally, the parts produced by the dies needed to be presented to automation for processing in the same manner as originally intended.
Working closely with the customer’s engineering team, the Die Technology tool design team recommended completely new matched metal blanking dies using robust mono block die construction for ultimate precision. The design optimized the advanced high precision manufacturing processes: Wire EDM for one micron profile tolerance of the punches, die plate, and stripper plates; jig grinding for ultra-high precision alignment, and conventional (sinker) EDM for punch cavity relief and stepped die relief. Carbide punches and die blocks were recommended for maximum durability.
Results That Exceeded Expectations
(Matched metal die for non-woven fiber material)
The outcome showcased superior quality, optimized efficiency, and proven longevity.
- Superior precision – Excellent part quality due to controlled cutting clearance
- Outstanding durability – Dies consistently run 10 to 15 million cycles per sharpening
- Maximum uptime – No machine shutdowns due to die failure or inconsistent cutting
- Easy maintenance – Routine cleaning and lubrication performed without removing dies from the line
- Quick changeovers – Dies designed for changeover in under 15 minutes when sharpening is needed
- Business growth – Success led to referrals within other divisions of the customer’s organization
Building Lasting Partnerships
This project became more than just a successful die solution—it established Die Technology as a trusted engineering partner. The customer has since referred us to other divisions within their organization, and we continue to support their manufacturing operations.
What made the difference wasn’t just our technical capabilities, though our 35+ years of experience with precision tooling certainly helped. It was our willingness to truly understand their specific challenges and collaborate on solutions that addressed both immediate needs and long-term manufacturing goals.
Every manufacturing challenge is unique, but the principles remain the same: listen carefully, engineer thoughtfully, and deliver solutions that perform reliably in real-world production environments.
Have a complex manufacturing challenge of your own? Connect with Die Technology to explore how our precision tooling expertise can support your next project.