Die-Cut Stripping Optimization
I resolved a die-cutting issue where tight cut geometry prevented waste from stripping cleanly, requiring manual removal during production.
I redesigned the problematic intersection to improve stripping reliability. The solution was adopted as a standard for future designs using the same construction.
Client
Confidential
Type
Manufacturing Optimization
Year
2022
Process
Identifying the stripping problem
During a pre-production trial, waste repeatedly failed to strip cleanly. I traced the issue to radiused cut lines converging into sharp points that unintentionally retained the scrap.
Designing out the failure
I replaced the sharp intersection with a small rounded relief that allowed the waste to release cleanly. Because the feature was concealed, the change had no effect on the finished carton's appearance or function.
Standardizing the solution
The revised geometry resolved the stripping issue and simplified the intersection for die making. The relief was then incorporated into future designs as a standard feature.
Outcome
The modification eliminated a recurring source of manual stripping and production disruption. The solution improved manufacturability across recurring high-volume work without changing the finished package.
