As your production volumes increase, however, these tools add cost. This is when and where the flexible circuit fabricator looks at die cutting as an alternative.
While our Guide to PCB Steel Rule Die Cutting vs. Die Cutting with Etched Dies explores the most common die cutting methods, this article takes a deeper look at Class A dies.
What Are the Types of Die Cutting?
Die cutting offers much higher volume production at a much lower cost than the routing alternatives above. Die cutting can accommodate thousands to millions of impressions, depending on which method is chosen and what materials are being cut.
Steel rule die cutting is the least expensive technique. Dies typically cost a few hundred dollars with a lead time of under a week. Although inexpensive, they are relatively inaccurate with a typical tolerance greater than ± .010” (0.254 mm). You can typically expect 1,000 impressions or less, depending on the features required and the material being cut.
Etched die is the next step up in terms of lifespan and accuracy. These typically cost a few thousand dollars each but offer greater accuracy, typically ± 0.002” (0.0508 mm) to ± 0.003” (0.0762 mm). They also provide the fabricator with a substantial improvement in life due to their steel base. You can typically expect tens of thousands of impressions depending on the features required and the material being cut. They can also be re-sharpened, further extending their useful life.
Class A dies, however, are the pinnacle of high-speed progressive die cutting.
Types of Die Cutting: Class A Dies
Class A dies are fairly rare in manufacturing flexible circuits and heaters. They are useful for very high-volume applications that require high-speed progressive die cutting with great accuracy, usually ± 0.001” (0.0254 mm).
Class A dies are very expensive, typically ranging from $5,000 to $30,000. They are built with very high-quality materials to provide long life, and components can be replaced and upgraded over the life of the die. You can typically expect hundreds of thousands to millions of impressions out of a Class A die, depending on the material being cut.
They are also quite capable of cutting thicker materials, such as stiffeners or excising flexible circuits with stiffeners out of the production panel, as well as cutting smaller features than a steel rule or etched die.
Class A dies can be used in combination with both types of die cutting (steel rule or etched), depending on the accuracy required, the material being cut, the volume and cost of the project, and end boards.
Can High-Speed Progressive Die Cutting Be Combined with Other Techniques?
The three types of die cutting can be used in combination with the lasers, Zund or routing machines. For example, the outside profile of a flex circuit might be very critical for the customer, say ± 0.002”, requiring a laser or an etched die.
Whereas the stiffener may be less critical at ± 0.006”, in which it would be appropriate to use a routing machine and then laminate the flexible circuit to the stiffener at a later stage.
Why Choose All Flex Solutions?
Determining the most effective approach to cutting and fabricating materials requires careful consideration before laminating them into the finished circuit product.At All Flex Solutions, we help you navigate these decisions with expertise.
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