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6 Your Cutting Room
Development, Innovations, Savings

EXPERT'S ADVICE

rygasiewicz

TOMASZ RYGASIEWICZ
Head of the Sales Department

Phone number: +48 604 613 132

Cutting large outlays on automatic cutting machine.

Cutting large material outlays is a complicated process, especially for materials such as artificial leather, artificial fabrics, technical or of low air permeation are often a big challenge in the cutting process. Specifically for us, as our production process includes large outlays. Luckily, modern cutting machines have that option and specifications that improve the process.

Before we start cutting large outlays it is important to properly prepare the cutting file. We have to specify the puncture point of a knife, directions of cutting, and, in some cases, split or skip some cutting lines. It is vital in cases such as cutting difficult materials that tend to not stick to the cutting surface and move easily – in those cases factors such as the puncture point and cutting directions have great importance. Optitex program grants us the ability to accurately set up those, and many other, aspects.

We know from our experience that when it comes to cutting artificial leather and hot-melt materials these factors play a vital role.Another important factor is what are the capabilities of the automatic cutting machine. Smooth adjustment of vacuum force (allowing for any value to be set) makes it possible to select the optimal vacuum power for each outlay. A similarly vast scope in setting the dynamics of machine’s work, including speed and acceleration, as well as smooth knife-oscillation control are making the choice of proper setting easier so that the quality of cutting materials is as high as possible.Thanks to the shape-recognition algorithms we can automatically adjust parameters in specific cases, such as cutting arcs, corners, and partial cuttings. Cutting speed adjustment in those specific places prevents from any imperfections from appearing and has an impact on the high-quality of the cutting.

Sometimes, a large challenge during the cutting of large outlays is the bending of a knife, appearing mostly near arcs, that results in differences in cutting of lower and higher layers. If it cannot be prevented with basic parameters or if it is for performance or quality reasons that the work dynamics cannot be lower, different approach to the matter is necessary. The solution is found in a very rare knife unbarring function. A function that works differently on other machines is set to ensure that the knife is kept vertically and prevent it from bending during cutting, thanks to which both upper and lower elements remain in the exact same shape.While choosing a cutting machine it is good to pay a lot of attention to adjustable parameters and access to appropriate settings. Only proper adjustment of all the parameters of cutting according to the given set-up will allow us to achieve repetitiveness and quality of cutting elements.

Fabric melting during cutting process.

Fabric melting during cutting process is one of the most popular problems in nowadays cutting rooms that can lead to cutting issues and damaging the fabric. The main culprit here is the presence of heat during the cutting process. The higher the amount of synthetic, easily-melting components, the higher the melt rate that we observe during the process.

During the cutting, knife’s edge is slicing through the material but its sides, which take no direct part in the process, cause friction. This leads to heating up the tool and edges of the material even up to 220ºC (the temperature of a candle heating a tea is around 60ºC).

Thanks to understanding this process, we can prevent it. We strive to keep the temperature of the knife during the cutting as low as possible and to prevent transferring that heat onto the material.

Thanks to increasing the dynamics of the machine, f.e.. increasing the speed and acceleration, we have made it possible to avoid heat transfer.

Despite the high temperature of the knife, the cut is so fast that it spends too little time in one place to melt the material.

Another way would be preventing the tool from heating up. By controlling the knife’s oscillation factor (up and down movement frequency), we are able to lower the temperature to which the knife heats. In most cases, it is possible to find the right balance and completely eliminate the melting effect by means of parameters only. However, when the melting rate is too big, it might be necessary to use additional options on the machine.

Some machines have the option to install a knife cooling system in order to lower its temperature during its work. Those systems are based on different technologies and have various effectiveness, nevertheless, if melting is a big issue for us it is necessary to consider those options.

Another take on the matter might be lowering the friction between the knife and the material. Such solutions are very rare and limited to highly specialized machines (including UNICUT), and it allows for constant covering of the blade with thin layer of special silicone. Applied in that way, silicon reduces the friction, and hence that sudden temperature rise is avoided and the melting factor eliminated.

Our mission statement. DIS – Development, Innovations, Savings, we try to eliminate melting in a user-friendly way. Additionally, thanks to the access to modern and rare solutions we are able to often increase the workload, while maintaining high quality of the layouts that we cut out.

lukaszzajac

ŁUKASZ ZAJĄC
Cutting Technology Specialist

Phone number: +48 600 012 881

mkrupinska

MAGDALENA KRUPIŃSKA
Technology Specialist

Phone number: +48 881 923 814

How to create cutting layouts for patterned fabrics in upholstered furniture production?

For a while now it’s been easy to notice that there is a growing interest in furniture made in a nonstandard fashion, designed to meet the clients’ sophisticated taste. It can be seen how fashionable is furniture with floral or checked patterns right now. Patterned fabrics are a real challenge for the producers. The material is expensive, which is why while fitting the pattern, we need to keep in mind that its use must be optimised as much as possible.

Pattern on different surfaces of the model needs to match, so the cutting layout needs to be prepared, that would include such matching. The elements need to be placed in a way that the templates will not move in relation to the pattern. Proper cutting layout and the final effect in the form of well-cut material can be reached thanks to these three steps:

1. Element matching.
During the creation of key templates (those that have to match the pattern) we need to put proper values into the PDS module in OPTITEX program – partial cuttings or internal points for which we define the position regarding the fabric report (the repeating fragment). The size of the report can be defined in this phase or later, during the layout creation.

2. Generating the cutting layout.
In Optitex’s Marker module, by using additional Match module, we create the cutting layout based on the grid representing the pattern of the material.

3. Cutting according to the blueprint.
In order to reduce element’s displacement on the created layout in relation to the piled fabric (it is caused by the properties of textile fabric) we use a built-in camera. The camera is in the cutting head of the cutter. During the cutting, before cutting every key element, the machine stops and the cutting operator – thanks to the camera – is able to manually adjust the head and continue cutting after the adjustment.


These solutions allow for quicker, more efficient, and more effective preparation of the production material. Thanks to that we can ensure proper pattern matching on cutting elements with maximised use of the material.

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