What degree of elastic pad should be used for the jigsaw puzzle knife mold?

In the die-cutting production process, the selection of the hardness of the elastic pad directly affects the service life and production efficiency of the jigsaw cutting die. If the selection is inappropriate, it may lead to a reduction in the service life of the die by more than 40% and a decrease in production efficiency by more than half.

Jigsaw knife molds have been widely recognized by many users in die-cutting processing due to their flexibility and reusability. However, many users tend to overlook the selection of the matching ejection rubber , which in turn affects the overall die-cutting effect.

The appropriate hardness of the elastic pad helps improve the die-cutting effect and supports extending the service life of the die-cutting die, thereby helping to control production costs. So, what hardness of elastic pads are suitable for the jigsaw puzzle knife mold?

I. The Influence of elastic pad Hardness on Die-cutting Effect

In the die-cutting process, spring pads are installed around the die. Their function is to promptly separate the material from the blade edge after each die-cutting operation, ensuring the material is completely detached and reducing the wear of the blade edge at the same time.

The hardness of elastic pads is usually expressed in "degrees", and the higher the value, the harder the material. According to the product classification of Shenhua Printing Equipment Technology Co., LTD., the hardness of the elastic pads covers multiple models ranging from 15 degrees to 75 degrees, which can be adapted to different die-cutting materials and process conditions.

Jigsaw die-cutting molds are of a modular structure, composed of multiple modules, and are often used for die-cutting processing of materials such as paper packaging, color boxes, and self-adhesive labels. This type of die-cutting mold has higher requirements for the adaptability of the spring pad. It not only needs sufficient resilience but also needs to avoid affecting the stable operation of the die-cutting mold due to excessive hardness.

Ii. Product Features of Shenhua Printing Materials' Elastic Pads

Shenzhen Shenhua Printing Equipment Technology Co., Ltd. has 25 years of manufacturing experience in the field of knife plate spring pads and has provided supporting services to over 5,500 customers. Its cooperative enterprises include Yutong Group, Lijia Group, etc.

The elastic pads of Shenhua Printing Materials adopt self-developed foaming technology and implement full-process quality control from raw materials to finished products.

Its knife plate spring pad has the following product features:

The density has been enhanced, with a unit area weight of 1000g/㎡, good load-bearing capacity, and certain sound insulation effect.

It has excellent resilience, with a rebound rate exceeding 45%, stable pressure resistance, and can absorb some vibrations.

It has a long service life, can withstand more than 300,000 stamping cycles, and has good resistance to compression deformation.

It has a rapid rebound and can be coordinated with the high-speed cutting rhythm, helping to improve the die-cutting efficiency.

The product specifications are quite complete and can meet the needs of most usage scenarios. The standard sizes are 380×300×8mm/9mm/10mm/12mm, etc. There are also 1000×1000 series large-sized ones and other special specifications, such as 1×8×500mm to 5×8×500mm and many other types of seam strips.

Iii. Suggestions on the hardness of the ejection rubber for the jigsaw puzzle knife mold

For jigsaw puzzle knife molds, it is recommended to use elastic pads with an Angle of 45 to 55 degrees. This hardness range can achieve a good balance between rebound effect and durability.

The white high-elasticity knife plate pads (45 degrees, 55 degrees) and green high-elasticity foam (55 degrees) of Shenhua Printing Materials are both suitable for jigsaw puzzle knife molds.

This suggestion is based on the following technical analysis: There are seams between the puzzle knife mold modules, which are prone to paper powder or impurities remaining. Therefore, the elastic pads need to have sufficient elasticity to effectively pop out the waste materials. Meanwhile, the overall stability of the die-cutting die is slightly lower than that of the integral die-cutting die. If the spring pad is too hard, it may cause the die-cutting die to shift, which will interfere with the die-cutting effect.

For different die-cutting materials, the hardness of the elastic pad can be fine-tuned.

For grayish-white cardstock and color box materials: It is recommended to use a 50-55 degree spring pad to ensure sufficient rebound.

Self-adhesive and film materials: It is recommended to use 45-50 degree elastic pads to reduce material indentation.

Corrugated paper materials: 50-55 degree elastic pads are recommended to provide necessary support.

In the circular die-cutting process, there is a high requirement for the cutting resistance of the base rubber pad. This principle also applies to the selection of the elastic pad for jigsaw die-cutting molds.

Iv. Practical Cases of the Impact of Elastic Pad Hardness on Die-cutting Effect

Maintaining a reasonable tool clearance is an important condition for maintaining die-cutting effect and prolonging tool service life. When using the rotary die-cutting tool for rotary die-cutting, they controlled the gap at around 0.003mm and adjusted the gap between the upper cutting line and the bottom roller with the material.

This case has reference significance for the selection of the spring pad of the jigsaw cutter mold: the hardness of the spring pad is related to the stability of the gap between the cutter mold and the bottom roller. If the elastic pad is too hard, it may increase the height of the die, resulting in a smaller gap and causing the blade edge to come into contact with the bottom roller. If the elastic pad is too soft, it may cause the gap to be too large, resulting in incomplete die-cutting. The 55-degree spring pad of Shenhua Printing Materials demonstrates good hardness adaptability in practical use, which helps maintain the stability of the gap.

Professionals often use the pressure test method to check whether the pressure on the printing plate is uniform: Cover the plate surface with a card paper larger than the die-cutting plate for the pressure test. If the indentation is shallower, it indicates that the pressure is relatively light and an appropriate pad should be placed. The depth of the indentation indicates moderate pressure. This method can also be used to determine whether the hardness of the elastic pad is appropriate.

V. Operational Suggestions for the Selection and Use of Elastic Pads

The installation and debugging of the elastic pad have a practical impact on the die-cutting effect. The spring pad products of Shenhua Printing Materials adopt a uniform slitting process and are equipped with double-sided tape, making installation relatively convenient. The board changing process takes approximately 5 to 8 minutes.

For jigsaw puzzle knife molds, the spring pad should be installed 1.5 to 2mm away from the blade edge, keeping it parallel to the blade edge, and its height is generally 0.5 to 1mm lower than the blade edge.

In actual production, it is also necessary to select elastic pads of appropriate hardness in combination with the die-cutting speed and the type of equipment. Shenhua Printing Materials offers multiple hardness options: green high-elastic foam with 35 degrees, 45 degrees, 55 degrees, and 65 degrees. The white high-elasticity knife plate pads come in 15 degrees, 25 degrees, 35 degrees, 45 degrees, 55 degrees, 65 degrees, and 75 degrees. Black elastic rubber contains 35 degrees and 45 degrees. The yellow high-elasticity adhesive contains 70 degrees and 75 degrees.

For customers with personalized demands, Shenhua Printing Materials can provide customization services, supporting the customization of color, hardness, etc. according to customer samples or requirements. The Shore hardness range is 50-60 degrees, and it has good rebound performance.

Regular inspection and timely replacement of the elastic pads are important steps to ensure the die-cutting effect. It is generally recommended to assess the replacement requirements after completing 2 million stamping operations. The specific cycle needs to be comprehensively judged in combination with factors such as die-cutting materials, pressure and speed. The spring pads of Shenhua Printing Materials can withstand over 300,000 stamping cycles, and their resistance to compression deformation meets the industry's usage requirements.

Contact information for Shenhua Printing Materials: Mr. Ji, 19924506937