How to order cutting dies for the GM Finisher and how to set up the template files
1.1 - Calculating Multiple Cuts Around
1.2 - Calculating Multiple Around For Templates
2 - Ordering Die
3 - Special Shapes
4 - Metal to Metal (Knock Outs)
Definitions
Around = This is the direction around the mag cylinder (Think length of material as it unwinds). This is also height/vertical in illustrator.
Across = This is the direction across the mag cylinder (Think width of material). This is also width/horizontal in illustrator.
Mag Cylinder = This is the top cylinder on the new finisher that is magnetic, this is where the die is installed.
Die = This is a thin piece of metal that does the actual cutting.
Platen = This is the print "Table" the printer prints on, It's 36" Long.
Divisible = (Math) Capable of being divided by another number without a remainder.
Remainder = (Math) The number which is left over in a division in which one quantity does not exactly divide another.
Template = This is the file that will be used to set up a print file.
1 - Setup Template File
It's best practice to have the label rounded to the nearest 1/8"(0.125"). This approach helps reduce both the inventory of dies and the frequency of new orders required.
- Open the standard template for the material width you would like to use
- Incorporate your cuts into the designated cut layer, ensuring to position as many cuts as the artboard can accommodate. The cuts must be spaced at 0.125 inches.
The standard space between cuts is 0.125". This can be larger or smaller, though it's not recommended and will also need to be reflected on the order page that you aren't using the standard gap.
- The number of cuts you are able to fit on the artboard will be "Number Across" when you order the die.
0.75" across is the smallest you can do for machine applied. Anything smaller will be considered hand applied and will be slit by 2 or more and the waste will not be removed.
Labels smaller than 0.75" wont separate from the wast and cause lots of issues for the finisher.
- Set the artboard to have a height of the label + 0.125"
- Create a 0.2" square that has no fill and no stroke, put it in the top left corner of the artboard.
This "Invisible" square is very important as it set the space between frames, if this is off it will effect the ability to cut on the finisher.
- Group all the cuts and center them on the artboard.
- If done correctly you should have a gap of 0.0625" between the cut and the artboard on both the top and bottom.
- Lock all items within the layers, while leaving the layers themselves unlocked. This prevents pre-press from accidentally deleting or moving anything when building files.
- Some labels that are smaller than 6" around may need the template to be multiple frames in one. (See "1.1 - Calculating Multiple Cuts Around" section)
If multiple frames need to be on the file template, copy the cut however many times needed. Making sure that there is 0.125" between cuts.
The art board will need to be set to the height of the following calculation:
(Size Around + 0.125") * Number Around
Make sure the "Invisible" square is in the top left corner of the artboard
- Save the file in \\DATA-SERVER\Lexie Storage\!SOP\Die Plates\Templates using the correct file name format and as an Adobe Template file type (.ait).
- ppp ZZZxYYY RC .AAA (MWin 00#)
ppp=Shape ("SQ"-Square with no rounded corners, "rSQ"-Square with rounded corners, "Cir"-Circle or Ellipse (Stretched Circle))
ZZZ=Label size across
YYY=Label size around
.AAA=Corner radius (only for rSQ labels, remove the "RC .AAA" for SQ and Cir)
MW=Material width
00=Backing weight (40#,50#,44PK,87#)
Examples:
rSq 1.75x7.25 RC .125 (8.5in 50#)
Cir 2.5 (8.5in 44PK)
Sq 1.625x4.5 (13in 40#)
1.1 - Calculating Multiple Cuts Around
The optimum die size is 9"-14" around.
Minimum die around is 6"
Maximum die around is 22"
No more than 4 around if possible
Note: For every one around you need to add the gap as well(Should be 0.125").
So 3 around of a label that is 3.43" around would equal 10.665" die.
Note: File template doesn't need to be the same amount around as the die.
- You want to shoot for a number around that will fall in the optimum die size. So a label that is 6" around would be 2 around. Even though it is larger than the minimum, 2 around would make the die 12.25" around which fits in the optimum die size.
- To find how many around you want on the die take the label size around find out how many it would take to get to the optimum die size. You want to make sure that the number around stays below 4 if possible, even if that means it's less than the optimum die size.
1.2 - Calculating Multiple Around For Templates
- Your die around should be divisible by how many labels will print on one platen(36"). The printer will only print the number of frames that would fit within 36", it will never print Fractional frames.
- First find out how many frames will be printed on one platen. 36/(Label Size Around + 0.125") Remove the remainder from the solution, this will be how many frames will be printed on one platen.
- Your die around should be divisible by the number of frames that will be printed on one platen. If it isn't divisible then you need to add one more around to the template and repeat the math until you get a whole number.
Template Example 1:
- Label is 1.75" around.
- 36"/(1.75"+0.125")=19.2 Frames / Platen, Drop the remainder(.2) and you get 19 frames.
- 19 is a prime number so it is only divisible by 1. This means we couldn't have the die more than 1 around without making the template more than 1 around. So lets try to add one more around and see how that maths out.
- 36"/(2*(1.75"+0.125"))= 9.6 Frames per platen, drop the remainder(.6) and you get 9 frames.
- Since the template was 2 around you multiply 9 frames by 2 and get 18 labels / platen, which is divisible by lots of numbers so 2 around/up on the template will work great. Next we need to know how many around the die will be.
Die Example 1:
- We need to try to get to the ideal die size around (9"-14").
- Using the same size as the previous example (1.75" around), we will add our gap to the label(0.125") and multiply it by 2 (around), which gives us 3.75". This is both bellow the minimum and not in our ideal die size, so next we will do that math again, but multiply it by 3 (around). This gives us 5.625" which is just under the minimum die. So we will try again, but multiply it by 4 (around). This gives us 7.5" which is above the minimum and below our ideal die size, though we don't want to do any more around since that would then go over the maximum around for a die. So we will keep the die at 4 around.
- Now we need to verify that the number of labels on the platen (18) is divisible by the number of labels around on the die (4). 18/4=4.5 So we will need to go back and change the print template.
- So increase the number around/up from 2 to 3.
- 36/(3*(1.75"+0.125"))= 6.4 Frames per platen, drop the remainder (.4) and you get 6 Frames. Multiply the frames(6) by the number of labels(3) around/up and you get 18 again. We already know that 18 is not divisible by 4, so we will need to have the template be 4 around/up. Since the die and the template both have 4 around/up, we know they are divisible.
- So we will order a die that is 4 around and set up the die template to be 4 around/up.
Ordering dies for labels that are smaller than 3" can be a lot more difficult and will often result in the die and the template having the same number of labels around/up.