1. Application discovery
Gather web layout, liner types, adhesive calipers, gap targets, and die station data.
Guide
What is rotary die cutting?
Understand how rotary die cutting works, when to pick solid vs flexible rotary dies, and how Midway supports converters from concept through lifecycle service.
Rotary die cutting uses a cylindrical tool and anvil to cut, perf, score, or kiss-cut material as it moves continuously through a press. Because pressure is applied in a rolling motion, converters can hold tight tolerances at high speeds across labels, medical parts, gaskets, and technical laminates.
An MRD engineering review benchmarks the entire material stack—liners, adhesives, substrates, and target speeds—so the die geometry, steel, and relief pockets match how the product will actually run.
Key traits
- Ideal for continuous webs such as PS labels, films, foils, foams, and composites
- Supports kiss-cutting, through-cuts, perforations, embossing, and scoring in a single pass
- Relies on precise clearances between the die and anvil, so documentation and lifecycle tracking are critical
Rotary die cutting workflow
2. Engineering review
Model tool steel, relief angles, venting, and slug removal required by the dieline.
3. Tool build
Machine the die body, harden, grind, and polish edges; qualify on matched anvils.
4. Validation & setup
Inspect dimensions, document recommended pressures, and share setup sheets with operators.
5. Lifecycle support
Track run counts, sharpening intervals, and service history so replacements are proactive.
Solid vs flexible rotary dies
Best for long runs, abrasive materials, or multi-depth work
Solid rotary dies
- Through-hardened steel maintains edge life across foils, NVH foams, and dense laminates
- Supports dual-height cavities, bearer bars, and complex slug removal hardware
- Can be resharpened and tracked for years with inspection data and pressure notes
Best for short to mid-length runs and rapid changeovers
Flexible rotary dies
- Steel rule laminated to a magnetic backing installs quickly on standard cylinders
- Edge conditioning matches liner caliper so kiss-cuts on PS labels stay clean
- Lower cost per die makes it economical for promotional or prototype work
Where rotary die cutting shines
Application insight
Labels & packaging
Rotary die cutting for pressure-sensitive labels, shrink sleeves, and flexible packaging relies on polished edges and documented pressure ranges. Link projects back to our label product families to streamline changeovers.
Application insight
Medical & diagnostics
Medical rotary die cutting demands clean edges on breathable films, hydrogels, and adhesives while maintaining traceability for IQ/OQ/PQ. Engineering reviews confirm stack tolerances before production.
Application insight
Automotive & industrial
Rotary die-cut gaskets from foam, rubber, and sponge support NVH, sealing, and thermal needs. Tool steels, coatings, and lifecycle tracking help plants plan rebuilds without unplanned downtime.
Need help picking between solid and flexible dies?
Send your dieline and target run window—our engineers will recommend the tooling, coatings, and services to support it.