Digital die cutting solutions: precision, speed and flexibility with Kongsberg PCS

What is die cutting: advantages and challenges

Die cutting is a precision process used to cut, shape or form materials using a press and a die. It’s widely used across industries such as packaging and signage manufacturing. From corrugated board to rubber and foam, die cutting enables consistent, high-speed cutting of complex shapes with excellent edge quality and repeatability.

While die cutting is essential in many workflows, the process brings several challenges. Manual handling, lengthy setups, limited flexibility and tool wear can all impact productivity and accuracy. The good news: digital die cutting solutions offer a powerful way forward.

Key advantages of die cutting with the right setup:

• precise and repeatable results, even with complex shapes
• rapid cutting speeds for high-volume production
• clean edges with minimal material deformation
• reduced operator involvement through automation
• compatible with a wide variety of materials     

Typical industry challenges include:

• long setup times with conventional dies
• costly tooling adjustments or replacements
• limited adaptability for short runs or last-minute changes
• inconsistency in cut quality on tough or abrasive materials
• integration issues with modern production workflows

Why choose Kongsberg PCS for die cutting

Kongsberg Precision Cutting Systems delivers advanced digital cutting solutions designed to solve the toughest challenges in die cutting. Whether you’re working with packaging, signage, rubber or industrial materials, Kongsberg offers speed, precision and flexibility. From the smallest sample room to high-output production environments, our cutting tables and tooling are engineered to help you work smarter.

What makes Kongsberg PCS different:

• no need for traditional dies: digital tooling enables instant setup
• exceptional speed: maintain productivity without sacrificing quality
• smart automation: reduce manual tasks and increase throughput
• robust construction: ready to handle tough, industrial materials
• user-friendly software: intuitive controls and powerful integrations
• global support: expert advice and service, wherever you are

Digital cutting tables built for die cutting

Kongsberg cutting tables combine strength, accuracy and adaptability. Each system is engineered for digital die cutting applications across materials. Whether you're working with heavy-duty rubber or light corrugated board, Kongsberg delivers performance you can rely on.

Explore Kongsberg tables built to handle die cutting challenges:

• Kongsberg X: a versatile platform ideal for short-run production and prototyping. With fast tool changes and a wide tooling range, it’s perfect for converters who demand flexibility.
• Kongsberg C: built for high-volume production with ultra-high speeds and a steel tabletop. The C series ensures precision over time, even when cutting dense or abrasive materials like gasket rubber.
• Kongsberg Ultimate: engineered for continuous operation in industrial environments. This table offers the highest cutting acceleration in the market and unrivalled durability under heavy use.  

Each system includes multi-zone vacuum hold-down, integrated camera systems and automated tool calibration to streamline your production.

Tooling solutions that enhance die cutting

Kongsberg PCS offers a comprehensive range of cutting tools developed to maximize performance across different die cutting tasks. Designed for rapid swaps and minimal setup, these tools give you the freedom to cut, crease and perforate a broad spectrum of materials without compromise.

Top tooling options for digital die cutting:

• PowerHead: delivers high downforce and precision for cutting dense, thick materials such as rubber and foam. Its servo-controlled design ensures clean cuts, even on multi-layered substrates.
• CorruSpeed tool: ideal for high-speed cutting of single and double wall corrugated board without oscillation. It mimics the crush-free result of traditional die cutting while running significantly faster.
• Heavy-duty knife tool: offers strong, consistent force for straight cutting of tough materials. Designed for durability and precision, it’s the go-to tool for industrial applications.

Each tool is part of an ecosystem designed for easy setup, seamless integration and maximum productivity.

How Kongsberg PCS can help you master die cutting

At Kongsberg PCS, we understand the pressure to deliver speed, quality and reliability. Our cutting systems are designed to overcome the limits of traditional die cutting, providing digital alternatives that fit modern workflows. Whether you need faster turnaround, more material versatility or better consistency, Kongsberg is ready to help.

With our global support network, experienced teams and proven technology, we can help you transform your die cutting operations. From first consultation to long-term performance, we’re here to shape your future: together.