Ultrasonic Die Cutting

Ultrasonic die cutting involves a metal 'horn' made to vibrate like an audio speaker, but at an ultrasonic (outside human hearing range) frequency. When this vibration is applied to a material with a die under it, heat and pressure are generated. This will cause sealing of thermoplastic materials (either the edges of a single layer or bonding of multiple layers) and cutting given the proper blade configuration.

The most common uses of Ultrasonic is for sealing where the materials to be welded are sandwiched between the ultrasonic horn and an anvil. In the last few years, many applications have been developed to cut and seam materials between an ultrasonic horn and a rotating or not rotating blade. This operation is much like a sewing machine.

CRC has taken the technology to the next logical step. We apply the vibration of the ultrasonic horn to the material against a rotary die. This means that we can die cut and seal two dimensional shapes in a continuous process. This leads to higher productivity and the possibility of making larger and more complex shapes. At this point, we are still limited to 4 inches (100 mm) wide and about twice that length.

Ultrasonic die cutting is particularly desirable for:

• Cutting thermoplastic material that tend to fray when cut or handled (this method seals the edges)
• Making 'tea bags' and filter with clean, dependable sealed edges, free of charring and discoloration.
  
  

Ultrasonic rotary die cutting has its limitations:

• Only relatively thin materials can be cut.
• The cut parts can be maximum width of 4 inches (100 mm) wide and about twice that length.