Marbach targets large-format die-cutting with new dieboard

Marbach has introduced solidplate|alu, a lightweight dieboard developed for large-format folding carton cutting dies where dimensional stability, handling and repeatable precision are critical.

The solution is designed as an alternative to conventional multiplex dieboards, which can be affected by humidity and may offer more limited possibilities for repeated reknifing during their service life.

Three-layer construction combines aluminium and core material

The solidplate|alu uses a three-layer structure consisting of two aluminium outer layers and a marbacore core. This combination is intended to provide high dimensional stability while keeping the overall weight lower than comparable steel-based solutions.

Stable die geometry is particularly important on larger machine formats, where even small dimensional changes can affect registration and cutting consistency across the sheet.

Lower weight simplifies handling

Replacing steel with aluminium significantly reduces the weight of the dieboard, making large cutting dies easier for operators to transport, install and remove from die-cutting equipment.

Improved ergonomics can become increasingly important as die formats grow and converters handle frequent job changes. Lower weight can also reduce transportation costs when tools are shipped between manufacturing sites, die makers and customers.

Dimensional stability supports precise registration

Marbach says the solidplate|alu maintains accurate registration with steel counter plates, supporting consistent cutting performance during production.

Unlike wood-based multiplex boards, aluminium is not hygroscopic, reducing the risk that changes in environmental humidity will alter the dimensions of the dieboard and affect production stability.

Multiple reknifings extend tool life

The construction also supports repeated reknifing, allowing cutting rules to be replaced multiple times while the main dieboard remains in service.

Extending tool life can reduce the frequency with which complete cutting dies need to be replaced and help lower tooling costs across repeat packaging jobs.

Metal surface speeds up rubber replacement

The metallic outer layer allows ejector rubber to be removed and replaced more easily during maintenance and reconfiguration.

Faster replacement can shorten preparation and set-up times, helping converters return tools to production more quickly when rubber components become worn or need to be adjusted for a different application.

Large folding carton formats are key target

Marbach developed the dieboard particularly for large machine formats, where weight and dimensional stability become more challenging than on smaller dies.

The company sees applications across food packaging, pharmaceutical cartons and cosmetics, sectors where folding cartons frequently combine precise structural converting with demanding print and finishing requirements.

Tooling efficiency influences overall productivity

Although cutting dies represent only one part of the converting process, their weight, stability and maintenance requirements can influence press uptime, operator workload and production consistency.

By combining aluminium construction, lower weight and longer tool life, solidplate|alu is intended to improve both handling and process stability while supporting more efficient large-format folding carton production.