By Holger Beck and Jim Hingst
Heat transfer materials are
comprised of either polyurethane, vinyl or flock facestocks coated with a
heat-activated adhesive, and laminated to a plastic release liner or carrier
film. Plotter cutting heat transfer films is a little different than cutting
pressure sensitive vinyl. Some problems have resulted from using a dull blade.
Other problems resulted because the blade depth was set incorrectly or the
downforce pressure was too high. To help remedy these problems, I have compiled
a few basic tips and tricks.
Selecting the Right Blade
Most polyurethane heat
transfer films and flock films cut easily using a standard 45⁰
blade.
Thin, soft and elastic
materials may cut better with a 30° blade, because the cutting edge used is
longer and the more obtuse angle ensures that the material is not pushed in
front of the knife.
When cutting thicker materials
you may need to use a 60⁰ blade to ensure that the blade can turn easily.
Flock films, such as VelCut Evo, with
a thickness of 500µ seem to be thick, so many people use a 60° blade for
flock. But you don’t have to cut the flock fibers, you only have to cut the
hotmelt film and the flock adhesive and this is only slightly thicker than a
standard flex-film.
The more obtuse angle ensures again that the material
is not pushed in front of the knife.
Regardless of the blade angle
make sure that the blade is sharp, otherwise don’t expect clean cuts.
Adjusting Blade Depth
Not only for flock, but for
all material, one of the first adjustments that you should make in setting up
your plotter is setting the blade depth. The blade should come out of the blade
holder only for the thickness of the material to be cut. Setting the blade
depth much greater than necessary can result in dulling the blade faster, in a
faster attrition of the blade holder and the cutting strip. Cutting too deeply
into a release liner or carrier can also cause the blade to chatter resulting
in a ragged edge of the cut media.
The blade should cut
completely through the film and only slightly score the surface of the carrier
or release liner. You should never cut so deeply that you can feel the cut
lines on the backside of the carrier. Adjust the blade in its holder according
to your test cut results.
Adjusting Blade Offset
Blade offset is the distance
between the tip of the cutting blade and the center of the blade. This distance
will vary depending on the blade used. For accurate cuts, especially at the
corners, you must adjust your plotter’s offset setting to the manufacturer’s
recommendations. In many cases this setting is frequently ignored. Improper
settings are not difficult spot. A telltale sign that the offset value is too
low is that the outside corners are rounded off. Conversely, if the corners
protrude or end in a spike, the value is typically too high.
Downforce
Downforce describes the amount
of pressure (generally designated in grams) that is applied to the cutting
blade. Cutting polyurethane may take as little as 70 to 90 grams of pressure or
less. Generally, much less pressure than you need when cutting pressure
sensitive vinyl. Flock films will cut easily too, usually at about 100 to 120
grams.
The ideal setting is to use
the least amount of force to accomplish the job. If the plotter is not adequately
cutting the media, first check the cutting depth. If that is set properly,
adjust the downforce. In many cases the remedy is to decreases not increase the
cutting pressure.
Cutting Speed
When you’re plotter cutting
designs with intricate details, you will most likely need to slow your cutting
speed. Most people think that this is also true when cutting elastic heat
transfer films, such as FlexCut Sweet, which are very stretchable. But it’s not the case. With elastic materials you should also try to speed up your cutting speed. Ripe tomatoes, for
example, cut easier when you cut them quickly. The same principal holds true for flex film.
Test Cut
After you load the media in
your plotter and before you run a job always do a test cut. Check that the
depth of the cut is completely through the media but only lightly scoring the
carrier or release liner. Make sure that you cannot feel the cuts on the
backside of the carrier. Cutting too deeply is as much of a problem as not
cutting deeply enough.
If you are cutting square
shapes, one inside another, as part of your test cut protocol, check that the
corner cuts are precise. And if you cut concentric circles, see that the lines
meet cleanly after the blade makes a full circuit.
Troubleshooting
If you are following all rules
and still have problems, check the blade holder. The blade holder is the most
stressed part of the plotter. Make sure the blade turns easily and that there
is no play in the ball bearing. A drop of oil in the ball bearing can be
helpful. Otherwise think about replacing the blade holder.
Weeding Tips
- Cut a square around each text
line, so you can weed line by line.
- It sure helps if you can see
what you are doing. Good lighting is essential when weeding any type of plotter
cut films. For detailed work, a magnifying hood is great for weeding an
intricate design.
- Keep your work surface clean.
Dispose of weeded material so you don’t end up with extraneous piece
inadvertently stuck to the carrier of the applique and then heat pressed onto
the garment.
- Using a good weeding tool will
make weeding easier so you can be more productive. Everyone has a favorite
tool. For some, knifes, air release tools, or tweezers are the tools of choice.
Personally, I like the dental pick type of tool.
- Pick the centers of the
letters first, and then weed the outside matrix.
- When weeding plotter cut
graphics (reverse cut), start from the left side of the reading and work to the
right. For printed and cut graphics that are right reading, work from the
opposite direction.
FOR TECHNICAL
SUPPORT: SEF Americas provides a toll-free technical support service
at 844-720-9601. NOTE: If your
call is not answered by a tech support person during normal business hours, 8am
to 5pm EST (Eastern Standard Time), please leave a message and we well do our
best to return your call within an hour.
Should you need to contact us after business hours, an alternate tech
support number is 480-987-8028.
You can also get answers to your technical questions by emailing: techsupport@SEFamericas.com.
© 2015 Holger Beck & Jim Hingst













