Band Steel Cutting for Plastic Thermoformed Parts
Steel rule cutting is fast, inexpensive and perfect for small quantities
What is Band Steel Cutting?
Once a thermoformed part has cooled, it must be separated from the tool and any excess material removed. Band steel cutting is a punching process used for trimming. It belongs to the blade cutting category, as a cutting wedge penetrates the defined contour of the thermoformed part. The punching tool consists of a band steel blade set in wood and a punching counterplate.
Capabilities & Characteristics of Band Steel Cutting
| Feature for Band Steel Cutting | Specification for Band Steel Cutting |
|---|---|
| Cutting Line | Cuts with predefined break points (interruptions) |
| Edge Quality | Breakpoint tabs may be noticeable |
| Visual Appearance | Breakpoint tabs may be visible |
| Max. Material Thickness | Up to 4 mm (Best quality up to 1.2 mm) |
| Cut Misalignment Risk | Dependent on roller quality and transport accuracy |
| Borderless Punching | Not possible – a minimum 0.5 mm punching edge is required to prevent wall penetration |
| Adjustable Cutting | Possible with band steel cutting |
| Heating Capability | Possible up to 200°C (punch and counterplate) |
| Processing Temperature | - Demolding temperature for thick materials - Room temperature for thin materials |
| Risk of Deformation (Stringing) | Avoidable with heated punching tools |
| Tool Lifespan | 50,000 – 200,000 cycles (depends on material, thickness, and tool design) |
Advantages & Disadvantages of Band Steel Cutting
- Low tooling costs
- Quick machine setup times
- Freeform areas remain unaffected by post-processing
- Ideal for small production batches
- Longer production times due to separate punching station
- Shorter tool lifespan (100,000–200,000 cuts)
- More precise trimming achievable with combined forming-punching tools
Alternative Cutting Methods for Thermoformed Parts
Looking for other cutting methods beyond band steel cutting? We provide insights into alternative processes, including CNC milling and shear cutting.
