By Cassandra Balentine
Part one of three
The packaging and prototyping marketing space continues to evolve with demand for shorter runs, faster turnaround times, and better sustainability.
Digital die-less cutting solutions support these objectives by reducing tooling and material waste by allowing providers to only produce the packaging that is required. “Brand owners are also looking to validate designs more quickly through production-quality prototypes before committing to large-scale manufacturing. Versioning and personalization has also exploded over recent years providing fast responses to seasonal, regional and market requirements. As these trends continue, we expect digital cutting technology to play an even greater role in bridging the gap between prototyping and short-run production, providing the flexibility and responsiveness that modern packaging providers require,” offers Terri Winstanley, marketing manager, packaging and labelling division, Plockmatic Group.
Our October issue presents an in-depth look at the benefits of die-less cutting for the increasing role of digital printed prototypes and short-run packaging. Here we highlight select equipment well poised to meet the latest demands for digital cutting in prototype and short-run package production.
Graphic Whizard
Graphic Whizard’s Sinajet DF Series digital die cutters are designed for on-demand die cutting applications, making them a strong fit for prototypes, short-run packaging, custom boxes, folders, labels, greeting cards, counter displays, and other specialty print products.
For short-run packaging and prototype work, the Sinajet DF Series is especially well suited because it combines automatic sheet feeding, digital cutting, creasing, perforating, and kiss cutting without the need for traditional dies. This gives print providers the ability to produce one-off samples, short production runs, and variable designs with faster turnaround and lower setup costs.
The series offers multiple sizes to accommodate different production requirements, including the DF0604-MT with a 16×24-inch cutting area and the DF0906-MT with a 24×36 inch cutting area.
For larger format, short-run packaging and prototype applications, the Sinajet DF1007-MT with a 27.5×40 inch cutting area is especially well suited.
The Sinajet DF Series uses digital flatbed cutting technology with interchangeable tools for different applications. Depending on the job, the system can be equipped for rotary cutting, drag knife cutting, electronic oscillating cutting, creasing, perforating, kiss cutting, and pen plotting. The system also uses camera/mark registration and barcode-driven workflow features to help improve accuracy and reduce manual setup time.
Kongsberg
Kongsberg PCS offers multiple cutting platforms tailored to different production requirements for short-runs, to better fit the needs of different producers, rather than there being a one-size-fits-all approach.
The Kongsberg X remains the most popular platform for prototyping and low-volume short-run applications. This is due to its versatility, extensive tooling options, and modularity, which allows it to be upgraded as businesses grow or their needs change.
The Kongsberg C is increasingly being used for prototyping and short runs because of its speed, allowing it to keep up with even the fastest wide format printers, productivity and proven finishing quality on a range of materials.
The Kongsberg Ultimate is designed for higher volume short-run corrugated and display production and is particularly suited to runs in the hundreds and low thousands, where increased productivity is required while maintaining the versatility of digital cutting. The proven tooling options from the Kongsberg C are also available on this platform.
Kongsberg digital cutting tables portfolio uses a hybrid of advanced cutting technologies and tooling options —from advanced flatbed knife cutters to high-performance milling units. These are supported by advanced software and automation solutions to deliver dynamic mapping and better material versatility.
Plockmatic Group
The Plockmatic Group offers several model ranges that offer different solutions for prototyping and short-run packaging.
The Intec SC models offer automated sheet cutting from letter to B2-plus sized sheets and also offer kiss-cutting for self-adhesive labels and the FB models are a range of flatbed cutters of differing sizes and tooling options for media thicknesses from 1.4 millimeter thickness to 3.94 inches.
Plockmatic’s systems use a range of technologies for digitally controlled knife cutting with servomotor driven tool heads. The systems die-cut and crease with a combination of precision passive (drag/contour) knives and passive crease tools as well as active tangential cutting and creasing complimented by v-cur and oscillating tools (model dependent), optical camera registration to produce packaging prototypes, short-run packaging with the cost or delay of traditional steel-rule dies.
The packaging market continues to experience strong year-on-year growth, driven by ecommerce, sustainability initiatives, product personalization, and increasing demand for shorter production runs. This continued market expansion provides manufacturers such as Plockmatic with the confidence to invest heavily in research and development, accelerating the introduction of new technologies, enhanced automation, improved cutting and creasing capabilities, and smarter workflows. Ongoing investment in R&D ensures our solutions continue to evolve in line with customer requirements while helping businesses adopt more sustainable and efficient production methods.
Within the Plockmatic ColorCut range, the company has focused on developing workflow solutions that maximize productivity while simplifying operation. Features such as automated quick response (QR) code job retrieval, precision camera registration, unattended high-capacity feeding, and PC-free ‘No Wires’ operation have streamlined production and reduced operator involvement. At the same time, advances in its cutting and creasing technologies—including active tangential tooling, patented Reverse Side creasing technology, and intelligent software automation—enable users to produce production-quality prototypes and profitable short-run packaging with greater speed, consistency, and flexibility than ever before.
Summa
Summa offers a comprehensive portfolio of digital flatbed cutting solutions designed for packaging, displays, signage, and prototype production. The range is tailored to meet the needs of businesses of all sizes, from small design studios creating packaging samples to manufacturers running automated short-run production environments.
For sample making and design validation, the Optima V Series provides an ideal solution. Its static table design combines precision, ease of use, and a compact footprint, making it particularly attractive for companies where floor space and initial investment are important considerations.
The Omnia V Series addresses the growing demand for automation in B1 and B2 packaging workflows. Equipped with an integrated sheet feeder and catch tray, the system enables continuous operation with minimal operator intervention. This allows production staff to oversee multiple devices simultaneously, improving overall shop-floor efficiency while maintaining consistent output quality.
For businesses seeking maximum versatility and productivity, the F Series Vantage represents Summa’s flagship cutting platform. Featuring a robust conveyorized workflow, a broad range of tooling options, advanced packaging software capabilities, and the reliability of a brand with more than 50 years of industry experience, the F Series Vantage is designed to support both prototyping and demanding production requirements.
To further increase productivity and workflow automation, Summa systems can incorporate automatic tool, module, and blade recognition; automatic device calibration; conveyor extensions for longer material processing; barcode-driven job selection; unattended production workflows; and seamless integration with digital printing systems.
These capabilities make Summa’s solutions equally suitable for prototype departments, packaging development teams, and light-to-medium production environments.
Summa’s packaging solutions utilize digital knife-cutting technology, powered by a combination of oscillating knives, drag knives, creasing tools, rotary tools, and specialized modules depending on the application and substrate.
Unlike traditional die-cutting, digital cutting does not require physical tooling. Designs can be processed directly from CAD files, enabling immediate production and rapid design iterations.
Summa’s packaging solutions utilize packaging-oriented software technology, thanks to its high-end GoProduce software suite. Backside cutting and edge detection for a perfect creasing quality, Flute direction support for different flute pressure, tandem production for additional productivity.
Zund America, Inc.
For packaging prototypes and sample-making, the Zünd G3 digital cutting system offers flexibility and precision, enabling converters to quickly produce high-quality mockups without the time and cost associated with traditional tooling. This allows brands to accelerate design validation and speed products to market.
For short-run production, the Zünd D3 dual-beam system and the Q-Line—now available in both single- and dual-beam configurations—deliver true industrial-scale productivity. These platforms, and especially Q-Line with its unprecedented speed, offer high throughput, consistent quality, and various levels of material-handling automation.
These devices enable converters to efficiently produce short runs while also supporting rapid turnaround times and cost-effective production without the need for conventional dies.
Oct2026, DPS Magazine
