On the cutting edge

Finishing disciplines such as routing and cutting have traditionally been areas of sign and print production that were outsourced. However, with ever-innovative design and print solutions and the development of easier to use CNC and digital finishing equipment, bringing finishing in-house is becoming an increasingly viable option, if not a necessity. The number of new machines launched or seen for the first time in the UK at Sign and Digital UK 2015 bears witness to this.



Industry commentator Mark Godden observes: “Today, the needs of a typical signs and graphics manufacturer considering the purchase a computerised router are not as clear-cut as they once were. Most of today’s producers need to consider print as part of their workflow, and this has made calls on both traditional routing hard-ware, and on finishing systems, which creates appointments and needs that sometimes neither can keep—or keep up with.”

New kits on the block

It is against this backdrop that Complete CNC Solutions has recently introduced a new routing and knife-cutting production system from Protek. Known as the Unico TT, the system defines a new space for itself in the market as it is said to offer very accomplished standards of print finishing without giving away an inch in the production router stakes. This sounds like a single system that covers all ground and excels in both camps.



Julian Sage, managing director of Complete CNC Solutions, explains: “We’re long time-served in the business of selling and supporting routing systems and so we’re a bit more sensitive than most to the limitations that lightweight hardware with ambitions in the routing markets often saddle their users with."



“It’s not the most glamorous of features, but consider waste removal. Cutting resistant materials like foam boards and plastics of any thickness involves the removal of waste matter during cutting. Dieless cutting systems and typical print finishing hardware don’t have the capacity to cope with volume waste removal. That puts an incredible crimp in productivity. Work holding is another aspect that’s very limited. There’s only so much you can secure to a lightweight table successfully.”



Emphasising Sage’s point, the Unico TT looks over-dimensioned in practically every respect, with a massive robust chassis and the whole plot driven by helical rack and pinion drives. The spindle also looks as though it could power big tooling through the toughest materials without complaint and do so for as long as it takes to demolish huge workloads.



Sage adds: “Incredibly—and this is what makes the Unico TT such a ground-breaking system—the machine is also possessed of incredible finesses and accuracy. It’s a print finishing system without compromise. It has an automatic registration system that quickly sniffs out registration data in the prints it’s cutting. It then simply powers its way cleanly, and without any fuss at all using a combination of routing tools selected from the auto-changer or its knives, either reciprocating or static—both tangentially steered.



“The knife-holders handle a huge variety of cutting and creasing tools including a v-cutting knife for incising folding lines for mitred bends in sheets. The system cuts practically anything. All the usual suspects like foam and corrugated boards of course but, if you ever have need of something more exotic like composites, then bring it on.



“Unbelievably, work that comes off the bed of the Unico TT is finished to a standard that’s confused with both flame polished and laser-cut output. Glassy edges, ready to use with no further manual processes needed. This is a system capable of saving hours.


Sage concludes: “To wrap it up, in this one system, you have something that’s among the world’s most accomplished routing systems, highly productive print finishing and processing and the highest quality output ever seen from a router.”

Versatility and accuracy

Essex-based Blackman and White, which designs and manufactures its own range of large-format cutters, recently added the Versa Tech to its well-established MasterCut range. The Versa Tech offers a high degree of tool versatility and accuracy, with crease, kiss cut, router, drag knife, oscillating knife and driven rotary knife and laser all available on a single conveyorised or flatbed heavy-duty table.



Managing director Alex White comments:  “Customers can purchase one tool initially, then add others over time to meet increasingly varied production needs and spread the cost, and dual driven tooling with interchangeable ‘drop-in’ tools, both oscillating head and driven wheel, allows for easy and quick change of cutting technique.”

With the addition of a 2.5kW water-cooled router, the Versa Tech is able to cut widths up to 3.2m, and capable of long production runs on heavy duty materials such as acrylics and Dibond. The 100w laser is also a valuable option for textile cutting.

White continues: “The machine offers high-precision, top quality output with a fast return on investment. Because it runs on a linear rack, costs are kept down as no belt replacement is needed, and maintaining accuracy over time is ensured.”

Iraci Visual Media (Iraci visuelle Medien GmbH), based in NeuUlm, Germany, specialises in extra-large graphic display printing applications such as building wraps and interior displays, and uses the latest laser cutting technology to stay ahead of the competition in the large-format print market. The company has, therefore, invested in a 5m by 11m flatbed MasterCut from Blackman and White.

Together with a 5m UV-Printer and recently purchased 3.2m wide textile dye sublimation printer, the MasterCut enables Iraci to handle even the largest of soft signage jobs.

Andreas Iraci from the company comments: “As well as our high quality standards in terms of productivity, our customers benefit from truly bespoke solutions, tailored advice, and individual ideas. We produce bespoke extra-large prints on wide variety of media up to five metres for indoor and outdoor uses, and offer the perfect finishing in-house, including B. hemming or high frequency welding. Our experienced installation team also ensures the final assembly is right.”

The MasterCut flatbed cutter was custom-built for Iraci with a 60sq m vacuum bed offering a cutting width of about 5m over a length of 11m. The laser and knife option means they can precision-cut textiles, tarpaulins, special shapes, stickers, Kömatex plates, sail cloths, carpets, leather, felt, rubber, films, and much more.

Iraci adds: “Our XXL laser cutting machine is amazingly accurate when it comes to cutting both textiles and rigid materials. It can deliver highly intricate and identical cuts for branded work, and the laser ‘welds’ the cut edges of fabric together to eliminate the risk of fraying.”

Expanding on the details of the machine, White adds:  “The MasterCut is our most powerful, durable and versatile range, and all the models are designed to handle both the toughest materials and working conditions. Unique to our cutters is the ability to simultaneously knife and laser cut on the same machine, reducing the floor space needed for separate kit for each function.”

Elsewhere, new from Friedheim International, the Lasercomb ProDigi NEO 2517 large-format multi-functional digital cutting system is one of a range of machines specifically developed by Lasercomb for the high demands of the signage, display and packaging industries.



A modular tool concept is a key feature of the ProDigi NEO multi-functional digital cutting system, and the machine features three tangentially controlled tool holders that are capable of handling up to seven different tools, all of which can be quickly changed over as required.  The alternative tools include cutting/creasing/ drawing units and a 3D milling unit.

In addition, a new front end PC featuring a colour touch screen allows the operator to choose between automatic or manual modes, as well as accessing the tool database.  The PC also provides operational diagnosis. Head movement speeds of up to 100 m/min and built-in bed conveyor offer gains in increased productivity.

The new NEO also includes divided vacuum sections with electronic adjustment, automatic digital compensation of table flatness, digitally controlled Z-axis, data transfer via network (RJ45), and full digital drive.

The ProDigi NEO range of digital cutting tables comes in a choice sizes for maximum flexibility, from 2100 x 1300mm to 3100 x 2500mm.

Further-more, the NEO is equally suitable for use in an office environment as no compressed air is required, and the table is therefore near silent in operation. 

A creative concept

Mimaki’s exclusive UK and Irish distributor, Hybrid Services, has been delighted with the attention attracted by the new Mimaki CFL-605RT Compact Flatbed Cutting Plotter since it made its UK debut at Sign and Digital UK. The new machine offers both creasing and cutting capabilities and is designed to support immediate finishing of packaging and prototypes with its versatile functionality.

Stuart Cole, national sales manager, industrial products at Hybrid, comments: “The launch of the CFL-605RT at Sign and Digital UK enabled packaging companies, design agencies and their customer brands to see a unique, fully integrated, small-format flatbed print and cut workflow solution with which to produce prototype packaging or short run bespoke projects.”



The newest addition to Mimaki’s family of cutting plotters; the CFL-605RT is a multifunction flatbed cutter that can accommodate material sizes up to oversized A2 and features a variety of functions including creasing and eccentric, tangential and reciprocating cutting.

Constructional packaging design and development is at the heart of York-shire-based Concept Packaging, headed up by managing director Chris Hallam. A multi-dimensional team that works in global partnership with a number of blue chip packaging manufacturers to deliver its patented and innovative solutions, some years ago Concept invested in a Mimaki flatbed (a fore-runner to the CFL-605RT), which rapidly became an integral part of its design and prototyping provision.



The team at Concept specialises in unravelling global packaging challenges and subsequently patents packaging design solutions that are then licensed to manufacturers who bring the concepts to a manufacturing reality around the world.

Hallam comments: “Research and development is a key part of what we do here at Concept. We are a small team, but over the last 20 years have developed robust partnerships with packaging manufacturers, engineers, contract packers and plastic moulding companies, amongst others, to enable us to deliver multi-component packaging with multiple elements, such as cardboard, plastic and tin.”

O Factoid: As early as 1905 the first commercially produced router—three phase and almost 60 pounds—was marketed by the Kelley Electric Machine Co. of Buffalo, New York. From the 1960s, the power tool form of router became the more common form. O

An important part of the process is Concept’s full sampling service, which has been borne of the desire to create ‘true’ prototypes and quality samples leaving nothing to the imagination. A key element of the prototyping development involves the company’s Mimaki CF2-0912, a flatbed cutting table that cuts a variety of materials, that has been resident at the company for over 15 years. The CF2 has made possible the development of systems such as Concept’s patented rigid boxes, which, despite being rigid, have components that fold flat for shipping but come together to create something that far exceeds the original.

Hybrid’s Cole adds: “The CF2 embodies Mimaki’s long heritage in the industrial cutting arena. Seeing how central the Mimaki CF2 has been to Concept’s business for so many years is testament not only to its accuracy and productivity, but also its industrial build quality. Mimaki is world renowned for its inkjet prowess, so it’s easy to forget it was one of the pioneers of digital cutting and plotting equipment and the current crop of Mimaki flatbed cutters, such as the recently launched CFL-605RT comp-act flatbed cutter and creaser, are based on the same, proven technology.”



Also new from Mimaki is the CJV150 Series integrated printer/cutter provides high performance, creativity and versatility with vibrant ink types, including new Silver, Orange and Light Black, in a cost-effective package for sign-makers, display graphics professionals and print shops.  It features a versatile range of print and cut options, with printing speeds up to 56.2sq m/hr.

The CJV150 Series offers high quality printing and sharp, accurate cutting for hundreds of different applications, including metallic stickers, decals, die-cut labels, signage, vehicle graphics, banners, poster, POS, back-lit and exhibition graphics, garment maring, and canvas prints.

In addition, Mimaki’s patented die-cutting facility, which is incorporated into all its printer/cutters, eliminates the need for cutting forms and means that individually cut, easily removable stickers and decals can be supplied rather than in sheet format.

Designed specifically for digital finishers, the Trident Series of CNC routers offers the best router/knife combination in its class, answering the ever-growing demand for versatility.

With a newly streamlined triple head configuration consisting of a routing spindle, oscillating knife and tangential knife, AXYZ has developed a robust, multifunctional CNC machine for the digital finishing industry.

A redesigned twin knife unit benefits from new high performance servo motors delivering high speed knife processing, with results of up to 50 percent throughput improvements when compared to existing AXYZ models. Speed is coupled with functionality with an extended knife stroke allowing for blades up to 120mm long for thicker materials.



With standard options such as the live vacuum deck, the automatic zone management ensures optimal vacuum performance when processing thinner materials. This ensures optimal holding power, dramatically improved cut quality, whilst simultaneously improving reliability and accuracy.

Robert Marshall, vice-president market development at AXYZ International, explains: “AXYZ has delivered a dedicated solution to solve the traditional issues seen in the digital finishing industry, and with a variety of processing areas and configuration options, manufacturers can customise their machine for their every requirement.”

Cut to the chase

With such a range of equipment available to address a wide variety of applications and market sectors, what are the advantages for sign and graphics manufacturers of bringing finishing in-house? The key benefit, by consensus, can be summed up in one word—control, of a whole gamut of production and business processes.

White of Blackman and White comments:  “The main benefits of bringing finishing in house are better control of your margins and bottom line, and a guarantee of quality and increased finishing speeds across your output. If you outsource your finishing, you’re reliant on the availability, skills, and capacity of other companies to deliver for your clients, and at the mercy of costs that are out of your control – but with finishing built into your in-house work stream you can complete entire jobs on site with a faster turnaround.


“The sign industry is also seeing a major growth in the development of textile printing and soft signage, so having a laser cutter in-house, which seals the edges of fabrics with no risk of fraying, can eliminate the need to send products out for sewing and hemming on certain fabrics.”

White adds further: “A modular cutter like the Versa Tech in particular allows companies to invest in different tools as and when they need them, and to finish a vast range of different printed media using just the one footprint. The sign industry is always developing and innovating, and keeping one step ahead of the competition can be key to success.”

Friedheim’s marketing manager Neil Elliott concurs. “As with most other items of equipment, bringing the operation in-house provides far more control over the process involved in terms of being able to plan jobs better to fit in with other work, to meet deadlines more easily—particularly with last minute requests. It ensures consistent high quality, as well as saving costs in terms of transporting material to/from an external source. The benefits are clearly many and wide-ranging.”


Cole agrees that bringing finishing in-house saves time, retains control, and you can respond more rapidly, also noting that you are “no longer at mercy of suppliers”. He adds: “Cutters are regularly sold along with printers to enable in-house finishing. The CFL-605RT cutting plotter alongside its perfect partner, the Mimaki UJF-6042 compact flatbed printer, creates the ability to deliver an on-demand printing and cutting workflow which is particularly relevant to the promotional, event, cosmetics and luxury item markets.”

AXYZ’s Marshall expands on the theme, stating: “Purchasing a CNC Router offers a whole host of benefits which are often unachievable through outsourcing alone. First and foremost a manufacturer can inherently increase their profits, reaping the benefits of a true pricing structure as opposed to those suggested by outsourcing. As a result, manufacturers can directly benefit through increased profitability or alternatively pass the rewards over to the consumer, offering reduced prices and consequently becoming much more competitive.

“Faster turnaround, improved efficiency and strict quality control are easily visible. By maximising the factory’s capabilities, manufacturers no longer wait for results, no longer receive unacceptable parts and no longer pay over the odds for a process they can replicate in-house.”

“Control the future of your business by adopting a long term plan that can help manufacturers diversify their business and approach new areas of the market. The purchase of a CNC router often sees sign-makers commonly expand into 3D signage, mould making and many more applications.”

Marshall adds: “Most importantly, bringing finishing in-house allows manufacturers to offer a ‘just in time’ service that can set your business apart. Customers may want to change their design or add further stock to the order, and whilst manufacturers continue to outsource their workload it is impossible to react to the changing demands of the customer.”


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