Multi-capable machines
There has also been a rise of ‘multi-capable’ machines, as more signmakers recognize the advantages of combining both routing and knife cutting in one system. It is now cost-effective to equip a single machine with a tangential knife cartridge (or two) and a spindle, which will allow a typical shop to handle more types of signs and graphics, while reducing manual processes.
Indeed, while most of today’s shops are well-equipped with machinery designed strictly for traditional signmaking, many signmakers are looking to expand their production capabilities further, diversify their offerings and serve a broader range of customers. For them, a multi-capable machine is a practical option, enabling them to fabricate everything from channel letters and light-emitting diode (LED) signs to decals and point-of-purchase (POP) displays with one system. With diversified output, they can hedge against future fluctuations in customer demand.
Short-run die-cutting has become more economical.
Vacuum hold downs
While a vacuum hold down remains an optional add-on for some CNC routers and knife cutters today, it has also become more standardized in the market.
Vacuum pumps draw air through the spoil board (for routing applications) or felt (for knife applications), providing suction for the parts being cut. Without a vacuum pump, these parts may move when pressure is applied from the cutting tool, causing the quality or orientation of the cuts to suffer compared to the initial design. This can lead to a waste of time and money.
So, while some CNC routers and knife cutters are still available today without a vacuum hold down, it is certainly a highly recommended option.
Automatic tool changing
The router option that is arguably the most useful for any shop, an automatic tool changer, is not exclusive to the sign industry.
A multi-position linear or rotary-carousel tool change system allows for seamless transitioning between different router bits. The capability to quickly switch between bits is especially important if a sign shop is using its router as a multi-purpose machine for a variety of different applications or for jobs that require more than one tool for efficient production.
The time saved from not having to manually switch bits between each cut can represent thousands of dollars in operating costs saved in the long run. In addition, signmakers can better predict their production times and schedule runs accordingly.
It is common for today’s CNC software to offer automatic layer toolpathing, which allows CAD files to be transferred directly to the machine, without having to manually create their toolpaths.
Automatic knife changing
In addition to automatic tool changers, some new machines incorporate automatic knife changers, so if an application calls for two or more knives or creasing tools to complete the job, the machine can switch them without needing operator intervention. The machines are being made more flexible with knife options as the number of materials to be cut increases.
Short-run die-cutting
In addition to the aforementioned options becoming increasingly standardized as add-ons for CNC systems that have already been on the market for years, there are also entirely new machine configurations and platforms available to extend the production capabilities of sign and graphics shops. One of the most notable improvements has been the ability to cut significantly faster than earlier machines.
Typically, a sign shop will specify either short- or long-run production using a knife or die, respectively. This is because the use of the die is costlier and its additional speed is not necessary when handling lower volumes of work; whereas using the die for long-run production will cut designs sufficiently faster than a comparable knife to warrant the additional expense.
Newer CNC and faster knife-cutting machines are aiming to close the gap between short- and long-run production. Previously, a run of 1,000 units would use die-cutting. Today, the number is closer to 10,000 units. So, the ‘breakeven’ point between traditional die-cutting systems and newer CNC/knife systems has increased dramatically.
