Hot Foil Printing Dies (March 2022)

I've been out sourcing printing dies but the lead-time was getting ridiculous especially when the dies are so easily damaged.

The cost wasn't so much of an issue but waiting for new dies could set production back a month or more.

I already produce the artwork and have experience with CNC machines and programming; not that you need much these days as the software pretty much produces the program for you, but a knowledge certainly helps when you need to tweak things.

I could use my Bridgeport milling machine which I converted to CNC some time ago, and I've done so in the past, but when using 0.2 diameter cutters the speed of a Bridgeport is too low at only 3000 rpm max . I could attach a high speed spindle but you have to remember these dies are only 25mm x 12mm so the text is only 1.5mm height, so its a big heavy machine for very fine work.

I decided to buy one of the cheap desktop CNC machines off eBay.

The software I use is Vectric Aspire. It does take some time to learn and has some strange ways of doing things when coming from an AutoCAD background, but it is a very powerful program which produces amazing results.

The other issue is cutter selection. Over the years I've been through so many engraving style cutters with varying results.

What I use is single flute 45 degree included angle with 0.1mm tip flat. My advise is don't always believe the description on eBay as some suppliers descriptions are very misleading.

If machine plastics you can get away with a smaller inclusing angle but I've found with brass an the fine details being machined that these tend to break very easily.

It does mean you have to adjust the spacing between elements to allow the 45 degree cutter to produce the detail. Luckily in Aspire you can adjust the space beteeen individual text letters easily.

Artwork produced in Vectric Aspire (LEFT) with simulation outpiut (Right)

Tool Path

Desktop CNC Setup

The finished print die. Not belwo that they are designed to print on a curved surface

A selection of finished dies

The printed item