3D Printed Paperboard Cutting Rules for Die-Board Integration
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Solution Overview
Problem
The labor-intensive and time-consuming process of preparing die-cutting and creasing tools for paperboard conversion limits production rates and increases costs, as each paperboard type requires custom tools and precise adjustments to achieve consistent and accurate results.
Innovation Solution
3D printing technology is used to manufacture cutting and creasing rules from materials like HDPE and polycarbonates, designing them to withstand forces and attach to the die-board, eliminating the need for traditional slotted die boards and allowing for customized geometries that enhance strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional steel blade rules are manually carved and shaped for die-cutting, then cutting precision can be achieved, but the process becomes highly labor intensive and time consuming
Solution Approach 1:
The patent replaces manual mechanical carving and shaping of steel blade rules with automated 3D printing technology. The 3D printing process automatically creates cutting rules with precise geometries based on digital models, eliminating the labor-intensive manual carving process while maintaining or improving cutting precision through computer-controlled deposition of material layer by layer.
Solution Approach 2:
The patent changes the manufacturing parameters and methods of cutting rules from traditional metalworking processes to additive manufacturing parameters. By controlling 3D printing parameters such as layer height, deposition rate, and material properties, the system achieves precise cutting geometries without manual intervention, significantly reducing preparation time while maintaining precision.
2Manufacturing precision
If custom die-cutting tools are prepared for each paperboard type, then accurate and clean cuts are achieved, but production costs and preparation time increase significantly
Solution Approach 1:
The patent creates a universal 3D printing system that can manufacture different cutting rule geometries for various paperboard types using the same equipment. The system uses digital models and programmable control to adapt to different cutting requirements, eliminating the need for separate custom tooling processes for each paperboard type while maintaining accurate cuts through parameter adjustment in the digital design phase.
3Strength
If traditional slotted die boards with steel rules are used, then cutting strength is sufficient, but the device complexity and labor for assembly increase
Solution Approach 1:
The patent extracts the cutting rule functionality from the traditional slotted die board structure. Instead of embedding steel rules into complex wooden or metal die boards with precise slots and mounting mechanisms, the system uses standalone 3D printed cutting rules that can be directly mounted or used independently, simplifying the overall device structure while maintaining cutting strength through optimized 3D printed geometries and material selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the labor and time required for tool preparation, increases production efficiency, and allows for the creation of carton blanks with precise cuts and creases, improving the overall production rate and reducing costs.
Implementation Method 1
a cutting and/or creasing rule 10 is produced on a 3D printing machine 12
Data Source
AI summary
A cutting and/or creasing rule is produced on a 3D printing machine which may be mounted on a board for use is a die for cutting and/or creasing a sheet of paperboard or other material into a blank for a carton. With the advent of additive manufacturing, i.e. 3D printing, it is now possible to eliminate traditional slotted die boards with generally rectangular steel cutting and creasing rules and replace same with surface printed boards with three-dimensional creasing and cutting rules.