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Plotting the Course of Business: Beyond the Manual
By Barry Campbell
When it comes to making vinyl plotters/cutters last and getting the most out of them, reading the owner’s manual is a good starting point, but there are many other things to keep in mind.
So many of the products used in our society seem to be designed with planned obsolescence in mind, that is they’re supposed to be worthless after a while so that the manufacturer can sell another one. Fortunately, since they cost a minimum of a couple thousand dollars, vinyl plotters and vinyl cutters aren’t designed for planned obsolescence.
Quality cutters/plotters can last a decade-plus, and many last longer than that. However, how much they’re used, what they’re used for, and other variables have an enormous impact on the endurance of this equipment. So it’s essential to keep in mind that a bit of tender loving care—okay, maybe that’s a bit of a stretch—can likely squeeze even more years and productivity out of a shop’s vinyl plotter/cutter.
With that in mind, let’s take a gander at some simple and relatively obvious—and some not quite so apparent—ways of getting the most out of a vinyl plotter/cutter.
Blow It Off
While the vast majority of cutters/plotters are relatively self contained and capable of long-term usage in significantly less-than-clean conditions, it just makes sense that keeping the working environment for these units somewhat clean will help them run smoother and longer. It’s not easy to keep a plotter/cutter clean, but there are a few quick things that can help out. Simply keeping any moving parts free of debris and dust buildup is a start.
According to Ken Pawlowski, director of digital products with Allen Datagraph in Salem, New Hampshire, it’s key to keep parts such as the drive rollers and pinch wheels clean. “You need to keep the drive roller clean because you can get adhesive and or material dust build-up on it, and then the grit surface will fill in and get slippery,” he explains. “Then the material you’re trying to cut can lose tracking accuracy and move back and forth.” Simply using a 50-50 mix of rubbing alcohol and water and a soft bristle brush to clean debris out of the grit roller can be a huge help, Pawlowski adds.
Rick Rivera, applications engineer in Roland Advanced’s Engraving & Cutter Solutions division, says dirt is to be expected in the sign shop environment, but that it is still not ideal. “Although quality-manufactured vinyl cutters will function in less-than-perfect conditions, graphics professionals should keep their work area relatively free of dust and other airborne contaminants,” he says.
Should the pinch wheels be left engaged while the cutter is not in use in the same spot for a long length of time, they will also develop a flat spot. Speaking of pinch wheels, it’s also important to ensure that they are properly positioned on the material that is to be cut. Pawlowski says that customers frequently forget to adjust the pinch wheels, which will almost certainly lead to inaccurate cuts. Then they call seeking technical support, when this common sense adjustment could alleviate the problem in the first place.
Bob Martz, with Chesapeake Graphics, Inc. in Westminster, Maryland, concurs that cleanliness can be a virtue when it comes to keeping plotters/cutters buzzing along smoothly. “Cleanliness is important with today’s cutters,” he says. “If dust builds up on the circuitry causing heat buildup, it can cause components to fail; but other than keeping them clean, cutters actually require very little maintenance and usually run for years without maintenance at all.”
Bobby Fosson, a technical support specialist for JSI Sign Systems in Atlanta, also says that the environment surrounding the cutter can affect longevity. “Most of today's cutter are not made like they used to be, and dust and debris can cause overheating of motors and lubrication problems,” he says. “If every operator would take five minutes at the end of the day to blow off debris from the cutter with canned air or an air compressor, they could extend the life of the unit for sure,” Fosson adds.
Cut the Static
While it might not be common knowledge, static electricity buildup can lead to a plotter/cutter’s early demise. Martz says that static electricity is one of the main causes of plotter/cutter failure. “We usually see a significant increase in repairs during the winter months here in the Northeast when the air is dry,” he says, adding that a humidifier or a can of antistatic spray can help alleviate static buildup.
Excessive moisture should be certainly by avoided when possible. Rivera adds that if static is a concern, placing antistatic mats in front of electronic equipment, including the cutters, can reduce static significantly.
Don’t Be Dull
Just as a gourmet chef requires sharp knives to chop food, a sign shop requires sharp blades on its vinyl plotter/cutter in order to achieve accuracy and productivity. It’s common sense, but allowing the blade to get dull is a sure way of slowing workflow and even producing inferior work. Additionally, selecting the right type of blade and cutting speed for the substrate to be cut is essential.
Another productivity-boosting key is to always plan out the work area to match the workflow. “You should take into account the workflow, from design to cutting to weeding to actual application,” says Rivera.
The most abused parts on most vinyl cutters are the protection strip, the blade holder, and the blade. “Consumable parts need to be replaced periodically,” Fosson says. “The cost of maintenance over the period of a year is very low, if not negligible, when compared to the amount of profit generated from these units.”
One part that should be changed very often, for units that offer them, are sheet cut blades. If left unchanged, dull blades and excess sheet cutting can lead to scan motor errors and possible burnout.
A sure sign that a unit’s blade needs to be replaced is when the pressure necessary to make cuts has to be incrementally increased. “When you have to start regularly increasing the pressure, it’s time to check your blade. If you’ve been cutting with a force of 12, and you’ve gone up to 35 over a couple of weeks, you’ve either dulled your blade or broken the tip right off it,” Pawlowski explains. Performing a test cut will ensure that the cutting depth is accurate before cutting the actual part.
The knife holder should also be inspected the from time to time since small pieces of vinyl can attach to the blade and can cause problems. Additionally, the cutting strip, or the Teflon® or plastic bed that provides backing under vinyl, can be damaged should the blade go through the substrate being cut. “If the blade cuts into this strip and damages it, the next time the blade attempts to cut vinyl over that area, it will depress the vinyl into the damaged area and not give a good cut,” Martz comments. “Or worse, it could cut through the paper and cause additional damage to the strip and possibly the blade.”
Some plotters/cutters have sheet cut blades, which need to be changed regularly. Fosson says that JSI recommends these blades be changed “on a monthly basis, if not more frequently.” He notes, “Dull sheet cut blades will cause excess stress and heat on scan motors and can lead to the motor burning up.”
Proper Eye Care
Another interesting recent development in plotter technology is the introduction of registration mark sensors to the cutters. This allows users to cut around contour cut graphics produced on large format printers. Some optical sensors are completely automatic.
Many new high-end units incorporate this technology to measure the substrate being cut. However, these “eyes” can become covered by dust and debris, which can lead to in accurate cuts. Some users don’t even realize the sensors are in the unit and, as a result, they don’t keep them clean and clear. While this is common sense and is surely referred to in the user’s manual, it’s a key maintenance item.
Fosson adds that in order to maximize production of any vinyl cutter, one must learn the operation and command menu of the unit. “The user’s manuals for most units are very thorough and should be read by all users,” he says. “Lack of knowledge on a particular cutter can lead to errors, mistakes, wasted vinyl, and stress on the cutter. (Fosson adds that good technical support from the seller, as well as the manufacturer, is crucial.)
Which brings up a good point: Most vinyl plotter/cutter maintenance is common sense and can be accessed and reviewed in the owner’s manual. While these units are dependable and simple to use, they’re flexible enough to cut a vast assortment of materials. They’ll be around for many years to come—and taking care of yours will ensure that your unit will also be around for years to come. Five minutes (or less) per day is a small price to pay for the smooth operation of such essential equipment.
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