Tags & labels - precision in perfection News | 12.06.2024

In industrial labelling technology, die-cutting tolerances depend largely on factors such as web tension, tool precision and material behaviour. For standard die-cut labels, the mechanical tolerances are in the range of a few tenths of a millimetre. However, this tolerance range is insufficient for use as technical stencils – for example, in precision component painting or automated assembly. Here, precise stencil manufacture within a range of a few hundredths of a millimetre is required. Even the slightest material elongation or tool inaccuracy leads directly to scrap in subsequent processing.

System design for absolute precision

S+P Samson GmbH has optimised the process parameters for rotary die-cutting in order to reliably maintain these extremely tight tolerances. A dimensionally stable special PET film, which exhibits minimal elongation under mechanical tension, was selected as the base material.

The technological foundation of the production line is a unit equipped with twelve separate tensioning devices. This system enables extremely uniform and finely adjustable web tension across the entire production length. To completely eliminate mechanical tolerances in the die, a specialised die cylinder is used, supported by a precisely matched counter-pressure cylinder.

Validation through high-precision measurement methods

The process optimisation of the stamped components requires adequate quality assurance to run in parallel. To provide comprehensive verification of the dimensional accuracy of the stamped precision parts at the micrometre level, an optical, high-resolution measurement method has been implemented. It is this precise measurement technology alone that validates that the moulded parts remain consistently within the required tolerance of one hundredth after the stamping process. This overcomes the technological hurdle for the industrial use of the dies in the factory.