Thompson-Boyd Manufacturing: Precision Perforating and Scoring Rules for Offset Presses, and Expert Die-Cutting Solutions for Custom Shapes and Designs

A Custom IOC (In-Line Offset Cutting) Die is an advanced, high-precision cutting tool specifically engineered to be used directly within an offset printing press. Unlike traditional die-cutting, which is a separate, offline process performed after printing, IOC dies allow for printing and die-cutting (or perforating, scoring, and kiss-cutting) to occur in a single, continuous operation.

These dies are typically thin, flexible, chemically-etched steel plates. They are designed to be mounted onto a magnetic cylinder that is integrated as a station in the printing press, usually after the final printing unit.

 The primary advantage is speed. By combining printing and finishing into one pass, it dramatically reduces production time, eliminates the need to move materials to a separate machine, and allows for much faster project turnarounds.

  Since the die-cutting happens on the same machine as the printing, the alignment (registration) between the printed image and the cut is exceptionally precise and consistent.

 The "custom" aspect means each die is chemically etched directly from a client's digital artwork or CAD file. This allows for the creation of extremely intricate and detailed shapes that are perfectly matched to the printed design. 

  Automating the finishing process in-line significantly reduces the manual labor and setup time associated with a separate die-cutting stage.

 Custom IOC dies are ideal for high-volume production of items that require precise cutting and fast turnaround, such as:

• Direct mail pieces with unique shapes
• Integrated labels and stickers
• Presentation folders and pocket mailers
• Coupons and promotional items with perforations
• Light packaging and cartons

A Custom PPP (Perf-Print-Plus) Die is a specialized on-press finishing tool manufactured to a client's specific requirements for perforating, scoring, or slitting paper directly on an offset printing press.

The standard Perf-Print-Plus system consists of thin, self-adhesive steel rules that are applied to the impression or transfer cylinder of a press. A "custom" PPP die refers to a configuration that goes beyond the standard, off-the-shelf product.

   Ordering a custom PPP die means the tool is created to the exact specifications of a particular print job. This can include:

• Custom Lengths: The perforating or scoring rules are cut to a precise, non-standard length to fit a unique layout.
• Specific Configurations: Multiple rules are pre-arranged on a single carrier sheet or template. This allows for complex patterns of simultaneous scores and perforations to be applied in one pass, ensuring perfect alignment and saving significant setup time.
• Unique Specifications: A request for a non-standard TPI (Teeth Per Inch) count, a special score profile, or other unique tool characteristics.

• On-Press Efficiency: Like all PPP products, it allows finishing to happen at the same time as printing, eliminating the need for a separate offline process and dramatically speeding up job completion. 
• Tailor-Made Solution: Provides a perfect-fit tool for complex jobs, ensuring accuracy and reducing the potential for error during manual setup.
• Versatility: The system can be used for a wide range of finishing applications, from creating simple tear-off coupons to scoring complex multi-fold brochures.
• Easy Application: The tools are designed for quick and easy placement on the press cylinder, minimizing downtime.

Precision Control: Allows for micro-adjustments to achieve the perfect cut depth.

• Protects Equipment: Prevents the sharp die from striking the anvil cylinder with excessive force, extending the life of both the custom die and the press.
• Consistent Quality: Ensures uniform cutting results from the first sheet to the last, reducing waste and improving job quality.
• Versatility: Enables the press to handle a wide variety of material thicknesses simply by changing the packing configuration.

A custom PPP die helps businesses create professional marketing materials and operational documents that are more interactive, functional, and effective.

• Direct Mail & Marketing: Create a direct mail campaign with a tear-off reply card, coupon, or business card. The custom perforation ensures the customer can easily detach the response portion.
• Billing and Invoicing: Print invoices or statements with a perforated remittance slip at the bottom. This makes it simple for customers to tear off and mail back their payment.
• Event Promotion: Design event tickets or invitations with a perforated stub for raffles, drink tickets, or easy entry tracking.
• Sales Brochures & Menus: Produce beautifully folded tri-fold or bi-fold brochures. A custom score ensures a crisp, clean fold every time, preventing cracking on heavy cardstock.
• Retail & Point of Sale: Make shelf talkers or product tags that include a tear-off coupon directly on them to encourage immediate purchase.

Schools can use custom PPP dies to streamline communication, organize events, and enhance fundraising efforts with materials that are easy for students, parents, and staff to use.

• Parent Communication: Send home flyers for field trips or events with a perforated permission slip at the bottom for parents to sign and return.
• Fundraising: Create professional raffle ticket books for a school fair or sports team fundraiser. The custom perforations make tearing and tracking tickets simple.
• Event Programs: Design custom-folded programs for graduations, school plays, or award ceremonies. Precise scoring makes them look polished and professional.
• Classroom Materials: Print sheets of flashcards or learning aids with perforations so they can be cleanly separated without needing scissors.
• Administrative Forms: Produce report cards or progress reports with a detachable section for a parent's signature and acknowledgment.

For personal projects and events, a custom PPP die allows for a level of polish and interactivity typically seen in commercial products, making your creations more memorable and functional.

• Wedding Stationery: Design an all-in-one wedding invitation where the bottom portion is a perforated RSVP card that guests can easily tear off and mail back.
• Event Tickets: Create custom tickets for a large family reunion, a significant birthday party, or a community block party, complete with a perforated stub for a door prize.
• Holiday & Greeting Cards: Make your own custom-folded greeting cards. A perfect score ensures a professional-quality fold, even on thick, high-quality paper.
• Personalized Recipe Cards: Design recipe cards that have a perforated shopping list on the side or bottom, allowing you to tear off what you need before heading to the store.
• Hobby Projects: Create sheets of custom game cards, bookmarks, or labels with clean perforations for easy separation.