Every die in Tools & dies knows the single-up it cuts. When you import a die file, quote a box or a CAD dieline, the shape is compared with the single-ups of your dies, so a die you already own is found without typing its number. A match shows as a chip ("Die on hand: D-2001 · 6-up"), and the quote uses the die at no die cost when it fits.
Exact and near die matches#
Two shapes are compared as cut: the outline, the inner cuts and the creases, turned and moved until they line up best. The largest gap left between them is the distance.
- Exact match: within the exact tolerance (0.25 mm unless you change it). The die is used automatically.
- Near match: within the near tolerance (1.0 mm unless you change it). It is suggested, never used until you confirm it. A shape with a different number of creases or holes is near at best, whatever the distance.
- Same box style and size: a box drawn in the Box designer and a die made for the same style, with each inside length, width and depth within the box size tolerance (1/32 in unless you change it). A die made from a Box designer box knows its style and size; an imported die needs its inside size and style in its box facts. A board caliper outside the caliper tolerance adds Different board caliper. It is only ever suggested, never used and never confirmed, because the drawn shapes may differ: its overlay shows both outlines without Use station A for this box. When the shapes are also a near match, the chip is near with Matched on style and size only.
A near match usually means the same die drawn slightly differently; two different cartons are rarely within a millimetre of each other.
Confirming a near match#
Click a near chip ("Near: D-1990 · 0.80 mm") to see the die's single-up and your box on top of each other, with the reasons. Use station A for this box confirms it for that box (or that artwork) once both outlines are drawn: from then on it is used like an exact match, and the chip reads "D-1990 · confirmed (0.80 mm)". Another customer's die can't be confirmed (the overlay says so), and one confirmed before shows why on its chip. The confirmation lapses when the shape changes; click the chip again to Stop using this die. Confirming is always your action.
When an import finds a near match among your single-ups, it asks whether the two are the same die. Different die: keep separate is remembered, so the question never comes back for that pair.
Match chips#
A box's Make section (Cartons and boxes) and the die import show the best match as a chip:
| Chip | Means |
|---|---|
| Die on hand: D-2001 · 6-up | An exact match you can use. |
| D-2001 · at the die maker (14 Oct) | An exact match that can't be used by itself now: the chip says why, and the tooltip lists every reason. |
| On hand, not used yet: Re-plan to use it | A die that fits was added after the box was priced; click it to plan the box again. |
| Near: D-1990 · 0.80 mm | A near match, suggested only; click it to compare the outlines. "same style and size" instead of a distance is a structural match. |
| D-1990 · confirmed (0.80 mm) | A near match you confirmed for this box. |
| No die on hand | No die of your library fits. |
A corrugated box is matched with the dies its die-cutter takes: rotary dies on a rotary die-cutter, flatbed (steel rule) dies otherwise.
Mirrored dies#
A left-hand and a right-hand version of the same shape are different products. A mirrored fit is listed with Mirrored and is never used to place artwork, because the print would come out reversed. For your library and for quotes you can let a mirrored exact fit count as a match with A mirrored fit is a match in the tooling settings. A die whose station is the left-hand twin of its single-up matches left-hand work normally.
Label dies#
Rectangular, rounded and oval label dies match by size, either way round: within 0.1 mm is exact, within 2 mm or 3 % is near (Different size). A rectangle is a rounded rectangle with square corners, so the two match each other; corners within 0.25 mm are the same, otherwise Different corner radius. Ovals match only ovals. A custom label shape is compared like a box.
Why a die isn't used#
A matching die lists its reasons on its chip. Some only inform; the ones marked "blocks" keep the die from being used automatically.
| Reason | Meaning |
|---|---|
| Mirrored | The fit is the mirror image (blocks placing artwork). |
| Matched on style and size only | Only the style and size agree, not the drawn shape. |
| Different board caliper | The die was made for another board thickness. |
| Different holes | One has a hole or window the other doesn't (often an artwork without the hang hole). |
| Different creases | The crease lines differ. |
| Different size | A label die of another size. |
| Different corner radius | A label die with other corners. |
| Made for another sheet size | The die is laid out for another press sheet (never chosen by itself). |
| Grain runs the wrong way | The die would run the board's grain the wrong way. |
| Doesn't mount on this die-cutter | Not on the die-cutter's list of machines it mounts on (blocks). |
| At the die maker | At the die maker (blocks unless you pick it). |
| Out for repair | Out for repair or re-rule (blocks unless you pick it). |
| Another customer's die | Owned by another customer (blocks: used only when pinned through the API). |
| Re-rule due soon | 90 % or more of its life is used. |
| This job passes its life | This job would pass its life: a re-rule is added. |
| No station layout | No station layout yet: quotes can use it, imposition can't place work on it. |
| Companion tool not on hand | Its stripping or blanking tool isn't on hand: that tool's cost is added. |
| No magnetic cylinder | A flexible die with no magnetic cylinder of its teeth on hand (blocks). |
Die notices on a box#
A carton or corrugated box that uses, or could use, a die on hand says so on its production card:
- New die cheaper: a die on hand is used, but a new die would cost less all-in at one of the quantities.
- Die for another sheet: a die on hand fits the box on another sheet size. It isn't used until the row is on that sheet. Die's sheet not available stops the box when you picked that die and the board has no sheet of that size, or the row's press or die-cutter can't take it: add the size to the board, or use a press and die-cutter that take it.
- Die doesn't mount: the row's die-cutter can't mount the die, so it isn't priced at no cost.
- Another customer's die: the die pinned through the API belongs to another customer.
- Re-rule due soon and Die life passed: the die is near or past the end of its life; past it, the re-rule is priced from the rate card's re-rule rate (or said to be unpriced without one). A quantity alternate that passes the life carries its re-rule.
- Die at the die maker and Die in repair: the die you picked is away.
- Companion not on hand: the die's stripping or blanking tool isn't on hand; its cost is added from the rate card, and Ready to quote asks for the rate card when there is none.
- New die late: a new die would not be ready by the job's due date, so it is never chosen by itself. A quote has no due date: its new die option shows the day it would be ready (from the rate card's lead time) instead.
Settings#
The tolerances, mirrored matches and the box size and caliper tolerances are in the tooling settings. Matching also runs through the API (Equipment API).