Vinyl cutters are vital for finishing print jobs like stickers and decals. Key factors when buying one include cutting force (up to 600g for tough materials) and the precision of the servo-motor drive system. While all-in-one printer/cutters save space, separate units may be more productive for high volumes and allow for easier upgrades.
Every form of printing will require some level of finishing even if that is only to add grommets. There are only so many applications where you just need to print a roll of self adhesive vinyl, particularly if you nest jobs together to save media costs. So in many cases those rolls will also need some degree of converting, which will usually mean a vinyl cutter. That could be for cutting out shapes or lettering from plain vinyl, or making stickers, or for separating graphics for dye sublimation or even Direct-to-film heat transfer.
However, there is a considerable difference between these cutters and the types of materials and jobs that they are intended to handle. Some are mainly aimed at producing simple decals and stickers. Others are designed to handle a wide range of thicker materials, complete with cutting around complex shapes. In some cases, these plotters can even be used for card, making them suitable for some lightweight packaging applications.
So what are the main features to take into account when choosing one of these cutters? For most people, price is going to be a major factor. But as with anything, you get what you pay for, and it’s not worth skimping on a cutting plotter. A good quality machine will give many years of service; a cheap device will just damage prints and force additional reprint costs. You will need to factor in some maintenance so look for a brand that’s established and well-supported to ensure parts availability over several years.
Otherwise the most important factors to consider are the cutting force and the drive system. The cutting force will determine the materials that can be handled. More basic systems will offer up to 120g of cutting force, which is good for paper and will be able to handle vinyl, but you will need up to 600g for tougher materials such as reflective films. Naturally, the plotter should offer several cutting options, including cutting right through the substrate, kiss cutting through the graphic layer but not the backing material and perforating. Some may offer different blades but for the most part they use a straightforward knife.
The drive system is harder to quantify though it should be based on servo motors. This system has to be able to accelerate the blades quickly to where they are needed, and then stop in exactly the right place. It must be able to handle contours and tight corners as well as to maintain a line over a straight path. It must be absolutely precise, cutting exactly on the line and nowhere else. And of course it must be fast to avoid any bottlenecks in production.
Together, the drive system and the degree of cutting force will determine the speed. Clearly, the faster the device can cut without sacrificing precision, the higher the overall productivity. But don’t forget that productivity also depends on how easily you can get the jobs on and off the device, and how quickly you can set up the files for those jobs. Ideally that means a network connection and a barcode reader to recognise jobs as well as suitable software. Most vendors will supply their own software, which should be able to work directly with Adobe Illustrator and CorelDraw to create the required registration marks.
Most vendors offer their vinyl cutters in a range of widths to match the printers they are intended to be used with, typically ranging from 60cm up to 1.6m wide. In most cases, the vinyl cutter will be brought for use with a particular printer but it’s worth considering buying the widest plotter that you have the space for in case you want to upgrade to a wider printer in the future.
Print and cut
Some printers include cutting features so that they can offer both printing and cutting. The advantage is that you only need to buy and maintain a single machine, and it takes less floor space than having multiple machines, which is a consideration for some smaller bureaux. This is fine for a relatively small volume of such work. But if you have a higher volume then it may be more efficient to use separate printers and cutters to avoid one process creating a bottle neck for the other.
The other consideration of course is price. An all-in-one device should be cheaper than buying two separate units. But the two functions will age at different rates. You may find, for example, that you want to replace the printer after a couple of years for a faster model with a different inkset, whereas your requirements for the cutting unit may not change that much. It largely depends on the applications the printer/ cutter is serving, and what other equipment you have available, as well as personal preference
In conclusion, cutting plotters in general may look a less complicated than a printer but don’t forget to schedule in regular maintenance, particularly around the media transport system. The blades should be replaced at regular intervals as worn or damaged blades will lead to tears, with the cost and delay of having to reprint jobs. Otherwise, it’s mainly down to keeping it clean and ensuring that there is no residual dust or media that can cause blockages. Properly looked after, a good vinyl cutter should last for many years, easily paying back its cost.