Abstract: A pair of rotary die cylinders having co-acting cutting blades formed by integral lands projecting generally radially outwardly from the main body of each cylinder and a method of making them by rough machining a tool steel workpiece with conventional cutting tools to form the general contour and path of the cutting blades and thereafter final machining and simultaneously heat treating the cutting blades with a laser to provide an accurately formed and hardened cutting blade. Preferably, the rough machining with conventional cutting tools and the final machining and heat treating by a laser are performed with the same machine tool, such as a computerized numerical control (CNC) machining center. Such a machining center permits rapid and accurate rough machining as well as accurate final laser machining of the cutting blades.

Abstract: A system to accurately align relative to each other a pair of rotary die cylinders having co-acting cutting blades formed by integral lands projecting generally radially outwardly from each cylinder. Each cylinder has an alignment groove formed therein such that when the cutting blades of the die cylinders are in alignment, the alignment grooves of each cylinder are aligned and define a slot between the cylinders which is constructed to receive an alignment pin. To initially align the die cylinders relative to each other, they are free to move both axially and rotatably relative to each other to permit the die cylinders to fully engage an alignment pin or pins inserted between the cylinders. Preferably, an alignment slot is provided adjacent each end of each cylinder with each slot constructed to receive a separate alignment pin to more accurately register or align the die cylinders relative to each other.

Abstract: Method and apparatus for repetitively making products, such as cap liners continuously from web material. A rotary knife drum having an array of die cutters cooperates with a counter-rotating anvil to thereby define a convergent web working zone therebetween. A pair of servo-motor driven nip feeders feed a web through the convergent work zone of the drum and anvil.