High Volume Fabric Cutting – The Benefits of Die Cutting vs Automated / CNC Cutting

Fabric Cutting – High Volume Manufacturing in Automotive Interior Trim Parts /Components

Benefits of Die Cutting Machine Press vs Weaknesses of Automated / CNC Cutting Machines

Operations, Cost & Quality Efficiency Comparison

Summary

The most commonly used fabric die cutting process is known as a “progressive feed” or “incremental” press. With the addition of a fully automated Die Vacuum system, this SCHWABE Straight Ram Beam Press cuts with the same incredible accuracy of a single-stroke press.

SCHWABE USA Straight Ram Hydraulic Beam Press with die vacuum cutting system.

The preloaded dieboard and hood enter the press as a single unit, and pressure is applied incrementally along its length as it moves through the press. The dieboard exits the press with the pieces accurately cut, and the hood is removed. Total cycle time is 1.5 min.

SCHWABE USA Straight Ram Hydraulic Beam Press with die vacuum cutting system.

Production Advantages

SCHWABE USA Straight Ram Hydraulic Beam Press with Die Vacuum cutting system

Advantages:

- - 100% cutting accuracy
  - Almost zero scrap parts
  - Tremendous productivity
  - Excellent fabric utilization
  - Material will not move while cutting

- - Pattern complexity immaterial to productivity. All interior blades and punches cut simultaneously
  - Each ply is consistently cut, top to bottom
  - Can easily cut 250,000 linear inches of material per minute

Materials:

- - Tri-laminates
  - Bi-laminates
  - High nap velours
  - Stretchy polyesters
  - Quilted material
  - Vinyls
  - Satins
  - Sponge or foam filled material

Watch Freeman SCHWABE YouTube Channel Video Demo

Quality Advantages of Fabric Die Cutting vs Automated / CNC Cutting

SCHWABE USA Straight Ram Hydraulic Beam Press with Die Vacuum Cutting System

- - High standards, low reject, and ease of sewing
  - Well suited for pour-in-place technology
  - Less steaming and finessing to achieve good appearance
  - More consistent covers and build
  - Fewer ongoing issues (looseness, wrinkles, wavy sews, tightness) because of poor quality n/c cut parts
  - Well defined notches
  - Consistent hole size with perfectly round shape
  - Perfect top to bottom ply comparisons
  - Very low rejection rate
  - Ease of sewing resulting in faster sew cycles and improved quality

Automated / CNC Fabric Cutting Machines

- - Lower standards due to machine variables
  - Inconsistent covers and build
  - Quality Issues (looseness, wrinkles, wavy sews, tightness) because of poor quality n/c cut parts
  - Notches are not consistent
  - Limited drill hole size (usually 2 per head)
  - Blade cut holes are not round
  - Substantial difference in top to bottom ply comparisons
  - Very high rejection rate (especially for PIP parts)
  - Difficult to use for pour-in-place technology