Steel-Rule Die Tooling, Crease Matrix Channel & Platen Die-Cutting Tonnage Calculator
Steel-Rule Die Crease Matrix Channel (W × D) & Platen Press Tonnage Calculator
How This Steel-Rule Die & Matrix Solver Calculator Works
On a flatbed platen die-cutter (such as a Bobst Autoplatine or hand-fed clamshell press), clean creasing and burr-free cutting depend on matching the steel creasing rule height, counter-matrix channel width (`W`), and channel depth (`D`) to the exact caliper (`T`) of the folding carton or corrugated sheet. If the matrix channel is too narrow, the outer paper liner cracks during folding; if platen tonnage is under-calculated, cut rules fail to kiss the hardened cutting plate. Our Steel-Rule Die & Matrix Solver computes exact matrix geometry, rule heights, stripping rubber load, and required press tonnage.
Governing Mathematical Equations (FEFCO / Bobst Flatbed Platen Die-Cutting & Counter-Matrix Creasing Standard)
Sizes the female phenolic/plastic counter-matrix groove so the board forms a crisp bead without cracking the outer printed liner.
Determines the exact height of the blunt creasing rule relative to standard 23.80mm (0.937") cutting knife stock.
Sums linear cutting resistance, creasing resistance, and 25% ejection rubber compression across all cavities on the die board.
Standard 23.80mm Steel-Rule Die & Counter-Matrix Sizing Chart by Board Caliper
| Board Caliper (T) | Crease Rule Pt (Width) | Crease Rule Height | Matrix Channel (D × W) | Specific Cut Force |
|---|---|---|---|---|
| 0.40 – 0.50 mm (300–350gsm) | 2 pt (0.71 mm) | 23.30 – 23.40 mm | 0.45 × 1.45 mm | 180 – 220 N/cm |
| 0.55 – 0.70 mm (400–500gsm) | 2 pt (0.71 mm) | 23.15 – 23.25 mm | 0.60 × 1.65 mm | 220 – 260 N/cm |
| 1.50 – 1.60 mm (E-Flute Board) | 3 pt (1.05 mm) | 22.40 – 22.60 mm | 1.40 × 3.20 mm | 140 – 180 N/cm |
| 2.80 – 3.00 mm (B-Flute Board) | 4 pt (1.42 mm) | 21.30 – 21.60 mm | 2.20 × 5.00 mm | 190 – 240 N/cm |
Apply These Calculations in 1:1 Parametric CAD Studios
Frequently Asked Questions — Steel-Rule Die & Matrix Solver
Why does solid bleached sulfate (SBS) card require higher cutting force per meter than E-flute corrugated?
High-density solid paperboard (350–500gsm) presents a dense, continuous cellulose cross-section to the bevel of the cutting knife, whereas hollow fluted medium crushes progressively before the liner shears.
What causes the outside of a printed box crease to crack when folded 180 degrees?
Outer liner cracking happens when the female counter-matrix channel is too narrow (`W < 1.5T + W_rule`) or the creasing rule is set too high, over-stretching the outer paper fibers beyond their tensile limit.
How much press tonnage is absorbed by the ejection rubber around the knives?
Closed-cell EPDM or Vulkolan ejection rubber compressed beside the cutting rules typically adds 20% to 30% extra vertical load on top of the pure steel-rule shearing force.