Bernal Crush Cut Rotary Dies: Precision, Durability, and High-Speed Performance
For decades, Bernal has set the standard in rotary die technology, delivering unmatched precision and longevity. Our Crush Cut Rotary Dies are engineered to provide the cleanest cuts at the highest speeds, making them the ideal solution for continuous web material applications across various industries, from packaging to medical supplies. Discover the features that make Bernal dies an industry leader.
Why Choose Bernal Crush Cut Dies?
Bernal pioneered the solid-hardened rotary die in the late 1960s, developing a proprietary wedge-type cutting edge on a solid-hardened cylinder using Electrical Discharge Machining (EDM). Since then, Bernal has delivered thousands of rotary dies renowned for high-quality cuts, exceptional speed, and compatibility with diverse materials and products—ranging from folding cartons and medical bandages to printed circuits, batteries, and even snack foods.
Key Benefits of Bernal Crush Cut Rotary Dies
Bernal’s Crush Cut Rotary Dies are constructed from solid, high-hardness tool steel, designed to precisely cut continuous webs of material. With exacting tolerances, these dies ensure exceptionally clean cuts at high speeds, optimizing throughput.
Outstanding Features and Benefits
- Machine Sharpening: Ensures precise, clean cuts with each use.
- Solid Steel Construction: Robust and durable for extended use.
- Segmented Options: Available in partially or fully segmented designs.
- Quick-Change Capability: Allows for fast setup and adjustments.
- Fully Hardened: Built to withstand rigorous, high-speed operation.
- Scrap Stripping: In-die scrap removal for efficient processing.
- Precision Cutting Tolerances: Achieves exacting shape accuracy.
Long Die Life with Resharpening
Bernal’s Crush Cut Dies can be resharpened multiple times, allowing each die to achieve millions of revolutions over its lifespan. After each resharpening, cut quality is restored to like-new condition, extending the value of the die.
Segmented Rotary Dies for Versatility
Crush Cut Dies can be partially or fully segmented with removable rings, ideal for cutting, embossing, marking, or laminating. These segments enable customization for different customer needs, maximizing the utility of each die across various applications.
Precision Specifications
Using advanced aerospace machining techniques and precision tools in our Advanced Machining Lab, Bernal manufactures each die to the highest standards with CAD/CAM, CNC, CMM, and EDM technology.
- Cutting Edge Accuracy: Within .001” (.025mm)
- Web Width Range: 1” to 110” (50mm to 2794mm)
- Die Diameter Range: 3” to 40” (76.2mm to 762.0mm)
- Run-Out Accuracy: Within .0001” (.0025mm)
- Hardness: 60-62 Rc
- Resharpening Capability: Up to 5 times
Expected Die Life by Material
- SBS Board: 40 million revolutions
- Poly Board: 80 million revolutions
- Lead: 8 million revolutions
- PVC: 5 million revolutions
- Sandpaper: 2 million revolutions
Compatible Materials
Bernal’s Crush Cut Dies handle a wide range of materials, including:
| • Poly Board | • Recycled Board |
| • Cloth | • Dough |
| • Lead | • Non-Woven Materials |
| • Sandpaper | • Laminates |
| • Polypropylene | • Fiberglass |
| • Paper | • Copper |
Why Choose Bernal Crush Cut Dies?
Bernal pioneered the solid-hardened rotary die in the late 1960s, developing a proprietary wedge-type cutting edge on a solid-hardened cylinder using Electrical Discharge Machining (EDM). Since then, Bernal has delivered thousands of rotary dies renowned for high-quality cuts, exceptional speed, and compatibility with diverse materials and products—ranging from folding cartons and medical bandages to printed circuits, batteries, and even snack foods.
Key Benefits of Bernal Crush Cut Rotary Dies
Bernal’s Crush Cut Rotary Dies are constructed from solid, high-hardness tool steel, designed to precisely cut continuous webs of material. With exacting tolerances, these dies ensure exceptionally clean cuts at high speeds, optimizing throughput.
Outstanding Features and Benefits
- Machine Sharpening: Ensures precise, clean cuts with each use.
- Solid Steel Construction: Robust and durable for extended use.
- Segmented Options: Available in partially or fully segmented designs.
- Quick-Change Capability: Allows for fast setup and adjustments.
- Fully Hardened: Built to withstand rigorous, high-speed operation.
- Scrap Stripping: In-die scrap removal for efficient processing.
- Precision Cutting Tolerances: Achieves exacting shape accuracy.
Long Die Life with Resharpening
Bernal’s Crush Cut Dies can be resharpened multiple times, allowing each die to achieve millions of revolutions over its lifespan. After each resharpening, cut quality is restored to like-new condition, extending the value of the die.
Segmented Rotary Dies for Versatility
Crush Cut Dies can be partially or fully segmented with removable rings, ideal for cutting, embossing, marking, or laminating. These segments enable customization for different customer needs, maximizing the utility of each die across various applications.
Precision Specifications
Using advanced aerospace machining techniques and precision tools in our Advanced Machining Lab, Bernal manufactures each die to the highest standards with CAD/CAM, CNC, CMM, and EDM technology.
- Cutting Edge Accuracy: Within .001” (.025mm)
- Web Width Range: 1” to 110” (50mm to 2794mm)
- Die Diameter Range: 3” to 40” (76.2mm to 762.0mm)
- Run-Out Accuracy: Within .0001” (.0025mm)
- Hardness: 60-62 Rc
- Resharpening Capability: Up to 5 times
Expected Die Life by Material
- SBS Board: 40 million revolutions
- Poly Board: 80 million revolutions
- Lead: 8 million revolutions
- PVC: 5 million revolutions
- Sandpaper: 2 million revolutions
Compatible Materials
Bernal’s Crush Cut Dies handle a wide range of materials, including:
| • Poly Board | • Recycled Board |
| • Cloth | • Dough |
| • Lead | • Non-Woven Materials |
| • Sandpaper | • Laminates |
| • Polypropylene | • Fiberglass |
| • Paper | • Copper |