Which Type of Cutting Die
Do I Need?
Greg Abdoo, Fremont Cutting Dies, Inc., Fremont, OH, USA
There are a variety of cutting dies avail-
able today—understanding which one you
need for your application is paramount. Se-
lecting the wrong die might not only be a
waste of money, but can also lead to provid-
ing an inferior product to your customer.
In this article, I will discuss seven differ-
ent types of dies: steel rule, Viking (pre-hard/
pre-sharp/clicker), forged, contoured trim,
machined, wire cut (EDM) and match-metal.
The first six have a sharp edge that cuts into
a poly-pad or directly against a hardened
steel plate, while the last, match-metal,
shears the material.
Diagram 1 Photo courtesy of Fremont Cutting Dies
6 The Cutting Edge
I will do my best to cover the basics. In
all my years I have yet to find this to be an
exact science—there is always a twist.
To help determine which die is best for
your application, we need to ask some ques-
tions:
• What material are you cutting?
• What is the volume?
• What type of press will be used?
• What is the size of the part?
• What is the shape of the part?
• What is the desired tolerance of the
finished part?
• And finally, how much money is in
your budget to invest in tooling?
The answers to these questions will typi-
cally get you pointed in the right direction.
Let’s begin with a look at the types of
cutting dies and some of their characteris-
tics. Please understand that the variables are
endless, and you should always consult with
your diemaker when considering buying a
new die.
Steel rule dies
These are constructed using a pre-hard/
pre-sharp steel rule die blade (see Diagram
1). Blades can range from 2pt (0.028" or
0.71mm) to 8pt. (0.112" or 2.84mm) thick
and have heights from 0.750" to 4" (19.05mm
to 101.6mm). The cutting edge can vary from
September 2016
serrated (many options) to center bevel to
side bevel.

Investment: Low
Size options: All but endless
Die life: Low to medium (10,000 to
100,000 impressions). Depending on lo-
gistics and die size, many times it makes
sense to have the die re-ruled once dull.
Once a steel rule die is dull, it cannot be
re-sharpened due to the case hardening
of the steel rule.
Diagram 2 Photo courtesy of Fremont Cutting Dies
Tolerance: From 0.010" to 0.060"
(0.254mm to 1.52mm), depending on cut-
ting rule selection and, more importantly,
the shape of the part that is being pro-
duced.

Viking (pre-hard/pre-sharp/
clicker) dies
These are constructed using a pre-hard/
pre-sharp cutting rule (see Diagram 2). This
material can range from 3mm (0.118") to
4mm (0.157") thick, in heights of 3/4", 1 1/4"
and 2" (19.05mm, 31.75mm and 50.8mm).
They also have cutting edges of serrated, cen-
ter and side bevel. One benefit of this style of
die is in most cases the operator can see
through the die and make better utilization
out of the material being cut.

Investment: Low
Size options: Any
Diagram 3 Photo courtesy of Fremont Cutting Dies
Die life: Low to medium (10,000 to
100,000 impressions). Once a Viking die
Die life: High (100,000 + impressions). A
is dull it needs to be replaced due to the
forged die can be re-leveled and re-
blade being case hardened.
sharpened many times as the heat treat
Tolerance: 0.032" (0.81mm) standard process is a through hardening.
Tolerance: 0.015" (standard) to as tight
Forged dies as 0.005" (0.381mm to 0.127mm).

These are constructed using special

forged rule, 4140 and S7 (see Diagram 3). Contoured trim dies
Rule thickness is normally 1/4" to ½”
This type is a machined die and striking
(6.35mm to 12.7mm) with almost unlimited
anvil that are mounted into a die shoe for
heights. The cutting edges are typically cen-
precision alignment (see Diagram 4).
ter bevel, straight inside wall (SIW) or
straight outside wall (SOW).
Investment: High
Investment: Moderate Size options: Basically unlimited due to
the unique construction of these types of
Size options: Medium to small
dies.

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 ADVERTISING CONTENT REMOVED
Die life: High (100,000 + impressions).
As with a forged die and many of the oth-
ers that are through hardened, contoured
trim dies can be re-machined and re-
sharpened many times.
Tolerance: 0.015" (standard) to as tight
as 0.005" (0.381mm to 0.127mm).
Diagram 4 Photo courtesy of Fremont Cutting Dies
Diagram 6 Photo courtesy of Fremont Cutting Dies
Diagram 5 Photo courtesy of Fremont Cutting Dies
8 The Cutting Edge
Machined dies
These dies are built using a solid piece
of 4140, S7, A2 or D2, to name a few options
(see Diagrams 5 and 6). Heights and bevels
are almost unlimited.
Investment: Moderate to high
Size options: Up to 20" by 42" (508mm
by 1067mm) on an average vertical ma-
chining center (multiple sections can be
used to make larger dies).
Die life: High (100,000 + impressions).
Like a forged die, machined dies can be
re-leveled and re-sharpened many times.
Tolerance: 0.005" (standard) to as tight
as 0.002" (0.381mm to 0.05mm).
Wire EDM dies
We build these with a solid piece of 4140,
S7, A2 or D2, to name a few options (see Dia-
gram 7). Heights go up to 7" (177.8mm) with
center bevel, SIW and SOW cutting edges.
See DIE TYPE page 10
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 DIE TYPE
Continued from page 8
Investment: Moderate to high
Size options: Up to 15" by 23" (381mm
by 584mm) on an average EDM.
Die life: High (100,000 + impressions).
Like a forged die, wire EDM dies can be
re-leveled and re-sharpened many times
with the proper bevel.
Tolerance: As tight as 0.001" (0.025mm).
Diagram 7 Photo courtesy of Fremont Cutting Dies
Diagram 8 Photo courtesy of Fremont Cutting Dies
10 The Cutting Edge
Match-metal dies
These are constructed using a solid S7,
A2 or D2, to name a few options (see Dia-
gram 8). Match-metal dies are a punch and
die mounted into a die shoe for precise align-
ment.
Investment: High
Size options: Any
Die life: Very high (1,000,000 + impres-
sions).
Tolerance: As tight as 0.001" (0.025mm).
Sample scenarios
The above mentioned are a good cross-
section of dies that are made/used for cut-
ting “soft goods.” Now, let’s look at different
scenarios and what die I would consider
based on various factors.
Testing/specimen
Volumes are typically low; however, tol-
erances can be as high as 0.001" (0.025mm).
I would suggest buying a wire EDM or ma-
chined die. Investment is higher, but you need
the tight tolerance.
Foam, 500 piece run
Tolerances are typically liberal and parts
can be thick. With such a low run, I would
suggest buying a steel rule die. The invest-
ment is low, it will hold tolerance and you
have many cutting edge options.
Thermo-formed plastics—single cutting
plane, 100,000 piece run
Tolerances can be tight and the mate-
rial can be difficult to cut without the proper
bevel and edge configuration. I would sug-
gest a forged, machined, wire EDM or a com-
bination of them. Because they are made of
steel, they can transfer and hold heat to help
cut through the material. They can also be
sharpened many times in the event your or-
der becomes a repeat. Steel rule can also be
considered, however, the dies will most likely
need to be re-ruled quite often.
Thermo-formed plastics—contoured cut-
ting plane, 20,000 piece run
Tolerance is probably not as much a con-
sideration as is the inability to crush cut the
product. If this is the case, I would suggest a
September 2016
contoured trim die. Yes, they can be expen-
sive, but the finished product will outshine
that of your competitor.
Leather glove, 5,000 piece run
Tolerances typically are not high on this
type of product. I would suggest buying a Vi-
king (PH/PS) die. Investment is low and you
have the added benefit of being able to see
through the die so you can easily avoid bad
sections of material.
Gasket, 3,000,000 piece run
Without question, you’re looking at a
match-metal die.
Paper placemat, 5,000 piece run
You will want to hold a 0.015" (0.381mm)
tolerance or better with this size of product.
With such a low run, I would recommend a
steel rule die. The investment is low, it will
hold tolerance and you have many cutting
edge options.
ADVERTISING CONTENT REMOVED
September 2016
Paper placemat, 200,000 piece run
Same as above, but a larger production
run. I would suggest a forged or machined
die. You now have the option of stacking your
product and cutting a 2" (50.8mm) stack at a
time. Production time is cut drastically.
As you can see, there are many factors,
and combinations of factors, in selecting the Take the time to
proper cutting tool for your application, and understand all these
there are just as many options for cutting dies
your die shop can supply. Take the time to factors and your
understand all these factors and your com- company can reap
pany can reap the benefits of choosing the
right die for the job.
the benefits of
choosing the right
Greg Abdoo is the owner of Fremont Cutting Dies, die for the job.
Inc., a one-stop shop for all of your cutting die needs.
For additional information, write to Fremont at
3179 US Route 20, Fremont, OH 43420, call 1-419-
334-5153 (toll-free 1-888-566-805) or visit
www.fremontcuttingdies.com.
The Cutting Edge 11