This article takes an in depth look at kiss cutting and its benefits.
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Kiss cutting is a method for cutting into a material where the upper layers are pierced, but the back layer is left intact. The term "kiss" refers to the way the blade touches the upper layers of the material and leaves a pattern or cut with a sufficient amount of force to leave an impression but not cut through the backside of the material.
Kiss cutting machines create a crack and peel surface for easy removal of the liner; this leaves the label or sticker to be applied to a package, envelope, or other surface. Kiss cuts are produced using digital die cutting machines that precisely control the pressure required to make the cut. A typical example of a kiss cut is a sheet of labels with multiples on a page.
Kiss cutting is used to produce gaskets or pads that can be rolled up for insertion into production or assembly processes. Gaskets in a rolled up form are easier to handle and can be positioned in a rolled up form to be dispensed like toilet paper or paper towels. Removing the part from a roll is easier than disconnecting them from individual sheets.
An essential part of the kiss cutting process is the adhesive liner. The die for the shape cuts through the lining and does not damage or harm the adhesive backing. There are several sizes of die cut parts from less than an inch to several inches or more.
Kiss cutting is performed by a variety of machines, from die cast cutters to laser cutters. The process of kiss cutting is a precision production method that requires control, accuracy, and uniformity to prevent cut throughs.
Rotary die cutting is similar to rotary printing where the shape of the die is cylindrical and mounted on a rotary press. The web of material is fed into the press that has the cylindrical die and an anvil. As the material is fed through, the cutting portion of the die presses against the web and anvil to pierce the material to imprint the design.
The rotary process is completed rapidly and ensures that the final image is properly aligned and uniform.
The main part of the flatbed cutting process is the steel rule, which is a series of sharp metal strips bent into the desired shape. The steel rule is placed on a hydraulic, electric, or mechanical press. The press has a feeder, in-feed module, cutting station, and steel rule die assembly.
The feeder pulls the material from the feed tray into the flatbed die press. In the cutting station, the steel rule die is connected to an upper plate. A lower counter plate, similar to an anvil, is below the cutting plate. When the material is in position, the cutting plate moves down slowly and makes contact with the material to make the kiss cutting impression.
Laser die cutting uses a laser to cut materials accurately and efficiently to custom shapes. The precision and accuracy of laser cutting allows for the cutting of complex and intricate designs at exactly the correct depth and dimensions. Since laser die cutters can be programmed to move in any direction and cut to any depth, they are capable of performing cuts quickly and effortlessly using input data and programmed requirements.
One of the more recent developments in die cutting is thermal die cutting, a process that can only be used on materials that can be shaped by thermal displacement. The method of thermal die cutting uses controlled heat to displace minute portions of material to achieve the desired shape. Though thermal die cutting involves concentrated heat to make the shapes and designs, it does not distort or damage other portions of the material.
Thermal dies are made of a magnesium alloy that has been chemically etched and is available in several sizes and thicknesses. One side of a thermal die is photosensitive, which makes the thermal process possible. A major benefit of thermal kiss cutting is the intricacy of the patterns that can be produced.
A cutting table functions somewhat like a flatbed die cutter but does not use a die to do the cutting. Instead, it has an arm that moves a cutting tool across the workpiece. Cutting tools can be mounted on one or more beams. There is a wide selection of blade types that can determine the depth and width of the cut. A programmable cutter controller tells the beams and cutting tools what operations to perform.
A kiss cutting module can be loaded onto a beam. Once it has been properly programmed, it quickly and efficiently cuts the impression into the substrate. The cutting tool can be set to cut at a precise depth, and it makes exceptionally clean cuts. Cutting tables specialize in kiss cutting vinyl and film.
A plotter kiss cutting machine is an automatic feeding cutting system that loads and cuts workpieces. It is capable of cutting a wide range of sheet sizes, from A4 up to tabloid size, or being fed a roll of material. Designs to be cut can be fed to the plotter from a computer or can be uploaded from a thumb drive. The depth and shape of the cut can easily be set from the machine's programming interface.
A computer numerical control (CNC) router is a cutting tool that is controlled by computer programming. A router is used to cut and shape a variety of materials and can perform several types of cuts. CAD created designs are translated into G code instructions for the CAM using vertical, horizontal, and perpendicular coordinates.
By attaching a kiss cutting knife cartridge to the Z axis, a CNC router is transformed into a large format kiss cutting machine. An adaptor is used to fit the kiss cutting knife into the existing spindle and tangential knife tools. The kiss cutting attachment has adjustable pressure settings, so it can be used on different thicknesses of material.
Hydraulic and mechanical presses are known for their ability to supply a great deal of force to cut hard, solid, and difficult to form materials. They can also be adapted for high speed kiss cutting using web feeding. Unlike the cutting of metals, the hydraulic and mechanical kiss cutting presses have a lower adjustable plate that can be set for the point of the cut as well as the depth. On each side of the lower plate are rollers that advance the material and guide it into the proper cutting position. For self-adhesive products, a rewind station is available to neatly collect the finished kiss cut material.
Clamshell kiss cutting machines are very similar to the old printing presses in that the material to be cut is placed on a platen or solid surface and the cutting tool is on the top half of the clamshell design. The term clamshell is an appropriate description of the machine. Like a clamshell, the machine has two sections—the upper half and lower half. When the machine is performing a cut, the two halves press together, and the die is pressed into the material being cut.
The designs of clamshell die cutting machines vary. In some versions, the upper half of the clamshell moves to the lower half, while in other versions, the lower half moves toward the upper half. Clamshell die cutters can be adjusted to cut any type of thickness and can be precision calibrated.
Kiss cutting is commonly found in the printing industry for use when labels are being printed. The pressure on the cutting press is reduced such that it cuts partially into the printed sheet. Kiss cutting dies and standard cutting dies are very much the same with minor differences.
Rule joints and miters have to be precision set to avoid cut through. Die cutters for kiss cutting are usually set at a depth of 0.937 cut to 0.918 cut. Unevenness in the stock can lead to uneven and imprecise cutting.
Steel rule dies are a simple form of die that is made by cutting slots in a rigid firm surface such as wood laminate, aluminum, rayform, acrylic, and Lexan. The size of the slot is between 0.028" and 0.056" (0.7 mm and 1.4 mm) and is normally cut by a laser. The slot is cut into the base in the shape of the form of the design to be cut.
A thin strip of steel, or rule, is inserted into the slot such that it sticks out above the slot and the surface of the base. The height above the slot and base is the depth to which the die will cut into the material. The upper edge of the strip is sharpened such that it is capable of cutting or piercing the selected material.
Thermal dies have excellent precision and can produce complex patterns. They are made from magnesium plates that have been chemically etched with a design. Thermal dies come in a variety of sizes and thicknesses and have a photosensitive emulsion coating on one side of the die. Graphic marking and kiss cutting of vinyl is a common use for thermal kiss cutting dies.
Rotary dies are made in the shape of a cylinder and come in two forms—flexible and solid. Flexible rotary dies are made of sheets of metal with the image to be cut engraved on the sheet. Solid rotary dies are a solid single unit cylinder that can be affixed to a rotary die cutter.
Flexible dies are less expensive and easier to produce than solid ones. They can easily be replaced when damaged. Flexible dies are attached to a magnetic cylinder that holds them in place. They are less durable, have a short life span, and are restricted in the materials they can cut. ,/p>
Solid rotary dies are more durable, can withstand constant use, and are able to make deeper cuts with higher blade designs. They are used for long runs and have an extended die life.
Optimum productivity is an aspect of production that every manufacturer strives to achieve. The timely assembly of parts and components is an essential part of business success. The use of kiss cut parts improves the handling and efficiency of production processes and assembly operations.
Parts produced using kiss cutting are attached to some form of backing such as silicone release liner or carrier tape. The parts are wound and delivered in rolls or can be cut into sections to fit the application. A major benefit of kiss cutting is its precision as the shape of a component is entirely cut out while leaving the backing.
Kiss cutting is one of the most popular methods used for the creation of pressure sensitive labels. During the process, the perimeter of each label is cut cleanly, allowing the peel off label to be easily removed. Labels can be produced in sheets or rolls in any shape, design, or configuration.
Kiss cut gaskets are made from a wide variety of materials, including rubber, vinyl, nitrile, and flexible graphite. The material to be cut is adhered to pressure sensitive adhesive backed material from which the shape of the gasket is cut. Rolls of gaskets are presented to assembly operators for easy removal and application.
During production, the ease with which self-adhering gaskets can be removed from the roll and applied to the assembly enhances production, increases efficiency, and saves time.
A goal of every producer is to make their label visible, distinct, and recognizable. Kiss cutting of iron on labels has become a major factor in the printing and designing of labels that can easily be applied to any type of fabric.
The kiss cutting process allows companies to design their label in a shape, style, and design that provides a professional and beautiful appearance that is easily readable. Labels can be produced in any size, configuration, color, and texture and have a smooth elegant appearance. They can include the company logo, employee names, and employee positions. The personalized nature of iron on labels adds a feeling of professionalism and stability.
Kiss cutting is used for creating adhesive tape solutions in a wide variety of shapes, sizes, and configurations. Adhesive tape of varying widths is fed into a kiss cutting machine. A die cuts the desired shape onto sheets or rolls. The pre-cut designs make it easy to remove the design from the rolls to be applied to any surface.
Adhesive tape shapes are used for car emblems, pricing labels, optical pads, abrasive materials, and other types of uses where immediate and convenient access to adhesive stickers is a necessity.
Any time a shallow cut is required, kiss cutting is used to complete the job. Kiss cutting is used to preserve and protect the backing or one side of a piece of material. Gaskets, valves, and plastic screen protectors are a few of the products or parts that are made using kiss cutting.
Though vinyl is one of the more common materials used for kiss cutting, there is an extremely long list of specialized materials that are shaped, configured, and transformed using the process. Essentially, any fabric that can be cut by a die is able to be kiss cut.
Kiss cutting is widely used in the production of gaskets and seals, which are fabricated in sheets or rolls with an adhesive liner. The materials used to produce gaskets and seals include various forms of rubber, polymers, and plastics that can easily be configured using the kiss cutting process.
Vinyl is a very common kiss cutting material and is widely used with thermal kiss cutting since it is capable of withstanding the heat involved in the process. Industrial kiss cutting of vinyl involves highly advanced computer controlled machines that have a coarse roller to track the feeding process. The reason that vinyl is so popular as a kiss cut material is that it is more durable than many of the other options.
Butyl rubber is a widely used material for gaskets since it is less porous than other rubber compounds and remains flexible at sub-zero temperatures. Gaskets made from butyl are tear resistant, are ideal for applications that involve gasses or compressed air, and have exceptional shock absorption properties.
The main features of closed cell sponge material are its resilience, high temperature stability, and inertness. It is available in soft, medium, firm, and extra firm densities as well as low compression and flame retardant versions. Closed cell sponge material comes in a variety of colors and can be customized to fit any application.
Viton rubber gaskets have exceptional thermal stability in high temperature applications. They are resistant to hydrocarbons, chemicals, fuels, and oil deterioration. These properties make viton gaskets the first choice of automotive, aerospace, and petrochemical manufacturers.
Kiss cutting is a popular method for designing and producing foil labels. Labels can be designed using any type of graphic design software using a wide array of colors, shapes, configurations, and fonts. Foil kiss cutting requires greater precision and care than kiss cutting of other materials due to the properties of foil.
Kiss cutting of stickers is the type of kiss cutting that most people are familiar with. Address labels, stamps, stickers for toys, labels on products, and yearly license plate stickers are made using kiss cutting. In all cases, stickers begin as a sheet of material (vinyl, paper, plastic, or some other type of fabric) that has an adhesive backing; it is put through a printing process that may include kiss cutting.
In some cases, once the stickers are kiss cut, they are weeded, which is the process of removing the material around the sticker for easy access to it. Strip or roll self-adhesive kiss cut postage stamps were introduced in early 1990.
As with kiss cut sheets of self adhesive stamps, kiss cut foam has become commonplace for adding self-sticking protection to the sides of containers and automobile parts. The protective quality of foam has made it ideal for use as gaskets or sealing material. The types of foam used for kiss cutting include closed and open cell configurations that can be adapted to any type of application.
The formability of foam is one of the main reasons that it is so widely used for kiss cutting die applications. It can easily be cut to precision dimensions using little energy or force.
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