Steel Rule Dies
Apple Steel Rule Die is the largest manufacturer of specialty steel rule dies in North America. Our manufacturing craftsmen have more than three centuries of combined die-making experience. This experience enables Apple Steel Rule Die to manufacture dies of all complexities from 7 mm, 1.5 point rule to 4″ high rule. We also excel at making dies using 6 point rule.
Apple uses several types of die base material including wood, rayform, acrylic, lexan, and aluminum.
The die-making process starts with our exceptional design team. The next step incorporates our many lasers to cut the design into whatever base material is chosen. After the laser process, our skilled die makers assemble each die with the aid of our state-of-the-art bending machines but still insert the steel rule into the die base manually. The final step in the process is to apply ejection rubber when requested and then prepare the die for shipping.
Apple is also the largest manufacturer of medical application dies in the U.S. Our medical dies use only FDA-approved materials that are applicable for both clean room and non-clean room operation.
Steel rule dies are used to cut thousands of substrates including, but not limited to, rubber, plastic, foam, paper, and cardboard.
We can reverse engineer your parts if you have no print or file. We offer complete inspection reports. We are also ISO compliant.
Our standard lead time is 2-3 business days from receiving purchase order, but depending on complexity of die, it may require longer lead time. We also offer same-day turnaround as well, depending on complexity. If you need same-day turnaround, please mention it on your request and we will let you know if possible or not once we review your files/prints.
Below is just a short list of the industries that we serve:
Printing and graphics, converting and packaging, thermoforming, gaskets, automotive, medical, flexible circuit rubber and foam.
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TWO STAGE DIES
We often see requests for dies where the width of a feature on a part is narrower than the thickness of the material. In some cases, it is too narrow to allow any ejection material between the rules. This lends itself to deformation of the parts, the part being stuck between the rules with no substantial ejection material on the die to release the part. Many times, the die will not hold up in these areas because of the pressure needed to cut.
Two stage dies are an option to this problem. Most of the time, these dies need to be used on a clicker press and need an operator monitoring the cutting process. These dies are on one base with two stages on the design. The first stage will cut interior cutout features and registration holes. The second stage will cut the perimeter after being placed over retractable pins that register the first cut to the perimeter cut. This process eliminates the ejection issue and creates a cleaner part with less cutting pressure. With this die design, it will take 102 impressions to create 100 parts. It can also be done on two separate dies, but in this case, 200 impressions are needed to cut 100 parts. The additional cost for the two stage die generally adds approximately $50 to $100 to the cost because of the additional punches and pins. The benefits reduce cutting issues and down time.
The drawing and die picture will help illustrate the process. Please feel free to contact us if further explanation is needed.
