Common Faults of Honeycomb Die Cutting Machines And How To Troubleshoot

Honeycomb paperboard is valued for its light weight and exceptional strength, making it widely used in packaging, furniture, automotive parts, and protective panels. But this same cellular structure also makes the material harder to cut. To achieve clean, accurate cuts, the die cutting machine must be perfectly calibrated—any small fault can cause crushed edges, incomplete cuts, wasted material, and production delays.

In practice, operators frequently encounter recurring issues. Drawing on over 20 years of machine-building experience at Wuxi Shenxi Honeycomb Machinery Factory, this guide summarizes the 9 most common faults our customers face when using honeycomb die cutting machines—and how to troubleshoot each one effectively. If you’re looking for solutions to cutting defects, die-cutting problems, or machine troubleshooting, this article gives you clear, practical, and experience-based answers.

What Is a Honeycomb Die Cutting Machine?

A honeycomb die cutting machine is specialized industrial equipment designed to cut, shape, and score honeycomb paperboard or cardboard into precise forms. Unlike standard paper, the thickness and cellular nature of honeycomb material require a robust machine capable of applying significant force without crushing the internal structure.

CE Honeycomb Panel Die-cutting Machine

Signs Your Honeycomb Die Cutting Machine Has a Problem

Before a complete failure, your machine will likely show signs that something is wrong. Paying attention to these symptoms can help you address issues proactively.

Visible Cutting Defects

• Crushed Edges: The edges of the cut material appear flattened or compressed instead of being sharp and clean.

• Uneven Cuts: The depth of the cut varies, with some areas cut through and others not.

• Torn Cells or Fuzzy Edges: Instead of a clean slice, the paper fibers are torn, leaving a ragged, “fuzzy” appearance.

Machine Performance Symptoms

• Excessive Noise or Vibration: Grinding, clanking, or shaking during operation can indicate loose parts, motor imbalance, or excessive strain.

• Overheating: The motor or hydraulic system becomes unusually hot to the touch, suggesting poor lubrication, blockages, or continuous high-pressure operation without adequate cooling.

Output Inconsistencies

• Dimension Deviation: The final cut pieces do not match the required dimensions, showing variations from one piece to the next.

• Repeatability Issues: The machine fails to produce identical cuts consistently, leading to high rejection rates.

Top 9 Common Faults of Honeycomb Die Cutting Machines

Understanding the root cause is the first step to an effective solution. Here are the nine most common problems operators face and how to troubleshoot them.

1. Incomplete Cutting or Not Cutting Through the Honeycomb Board

This is one of the most frequent issues, where the die fails to penetrate the full thickness of the material.

Possible Causes

Incomplete cutting often results from several technical factors working together. In many cases, the machine simply applies insufficient cutting pressure, meaning the force is too low to penetrate the full thickness and density of the honeycomb board. Another frequent cause is dull or worn die blades, which lose the sharpness required to slice cleanly through the cellular structure. Incorrect die height also contributes to this problem, as a die set too high cannot reach the bottom layer of the material. Additionally, the issue may arise when the honeycomb paperboard being processed is denser or thicker than the machine’s current calibration, causing the blade to stop short before completing the cut.

Troubleshooting Steps

To resolve incomplete cutting, begin by gradually increasing the machine’s pressure setting and performing test cuts until consistent full penetration is achieved. Avoid making sudden, large adjustments, as this can create secondary problems such as crushed edges. Next, inspect the die blades for dullness or damage; if they show signs of wear, replace them or have them professionally sharpened to restore proper cutting efficiency. It is also important to re-calibrate the die height according to the manufacturer’s recommended specifications to ensure the blade reaches the full depth of the material. For thick or high-density honeycomb boards, consider using a die with a steeper blade angle, which provides better penetration and reduces cutting resistance.

2. Edges Are Crushed, Compressed, or Deformed

When the machine cuts the honeycomb paperboard, the edges may appear crushed, compressed, or visibly deformed instead of showing a clean, vertical cut. This usually indicates that excessive force is being applied. The most common cause is excessive cutting pressure, which collapses the honeycomb cells before the blade even penetrates them. In some cases, the cutting speed is set too fast, creating a hammering effect that compresses the board. Another frequent issue is using the wrong die type—standard paperboard dies with flat or wide-angle blades tend to deform fragile honeycomb structures due to their geometry.

To solve this issue, operators should start by reducing the cutting pressure until the blade slices through cleanly without compressing the cells. Slowing down the cutting cycle also helps, as a gentler slicing motion prevents impact-related deformation. When necessary, switching to honeycomb-specific dies—which feature sharper angles or rounded blade edges—ensures the material is parted smoothly without crushing the internal core.

3. Ragged, Fuzzy, or Torn Edges

A cut that appears ragged, fuzzy, or torn is a strong indicator that the board is being torn rather than cleanly sheared. The most common cause is blunt or dull blades, which drag and rip through the fibers. Another cause is a misaligned die, where the blade isn’t perfectly perpendicular to the cutting surface and ends up creating sideways friction. In addition, incorrect feeding angle or skewed feeding introduces lateral stress, making the material tear instead of cutting smoothly.

Troubleshooting begins with replacing dull blades with high-sharpness steel blades, ideally those with polished cutting edges to reduce friction. It is also essential to check that the die is aligned correctly and firmly mounted, ensuring clean, vertical penetration. Lastly, operators must confirm that the board is being fed straight and held firmly in place, as stable, parallel feeding is critical for preventing fiber tearing.

4. Cutting Size Deviations / Poor Accuracy

When finished pieces show dimensional deviations or inconsistent accuracy, the issue usually stems from mechanical positioning problems. A loose positioning system—such as guides or stoppers that have shifted over time—allows the board to move during cutting. Another frequent cause is worn or slippery feeding rollers, which fail to push the material consistently. Additionally, thick honeycomb boards can exhibit material bounce, where their spring-like structure causes slight movement upon impact if not held securely.

To restore accuracy, operators should systematically inspect and re-tighten all guides and positioning elements to ensure stable material placement. Replacing any worn feed rollers will improve grip and reduce slippage. For large or thick panels, the use of stabilizers such as hold-down clamps, flattening plates, or vacuum tables ensures that the board remains perfectly still at the moment of cutting.

5. Machine Overheating During Long Runs

Excessive heat buildup in the motor, hydraulic pump, or bearings is a sign of machine overheating during extended production. This typically occurs when the machine operates under continuous high pressure, generating heat faster than it can dissipate. Poor lubrication also contributes to overheating because increased friction accelerates temperature rise. Another common factor is dust accumulation, which clogs ventilation paths and insulates internal components, preventing heat from escaping.

To manage overheating, operators should schedule periodic cooling pauses during long production runs. Ensuring all moving parts receive proper lubrication according to manufacturer guidelines will minimize friction. Finally, installing an effective dust extraction system and routinely cleaning vents, fans, and internal components is essential to maintaining a stable internal temperature.

6. Excessive Dust and Debris Inside the Machine

Honeycomb materials naturally generate large amounts of dust and fine debris during die cutting. Without proper extraction, this dust accumulates on dies, blades, and internal machine mechanisms. The primary causes are natural shedding of honeycomb fibers and the absence of a vacuum extraction system, which allows debris to accumulate and interfere with cutting accuracy.

To control dust, machines should be equipped with a high-power dust collection system positioned close to the cutting zone. Regular cleaning of blades, die holders, and internal components prevents buildup that compromises cut quality. Operators may also benefit from using anti-dust blade coatings, which reduce particle adhesion and keep cutting surfaces cleaner for longer.

7. Die Not Ejecting Properly or Material Sticking to the Die

When material remains stuck on the die after cutting, the problem is usually related to ejection failure. The most common cause is worn ejection foam or rubber, which loses elasticity and no longer pushes the material free. Sticky honeycomb boards with adhesive-rich layers can also adhere to the blade edges, worsening the issue. Another contributing factor is an incorrect ejection stroke height, which provides insufficient force to clear the die.

To fix this, operators should regularly inspect and replace worn ejection foam to restore proper rebound. Applying a light non-stick coating, such as silicone spray, minimizes adhesion on the die surfaces. Adjusting and re-calibrating the ejection stroke ensures the mechanism delivers enough force to cleanly remove the cut pieces.

8. Machine Vibration, Noise, or Unstable Operation

Excessive vibration, noise, or unstable machine behavior often signals mechanical imbalance. Over time, operational vibration can loosen bolts or structural fasteners, leading to increased instability. An imbalanced motor or bearings that are worn or failing can create grinding sounds and uneven motion. Additionally, cutting extremely dense honeycomb boards without adjusting settings may disrupt the machine’s rhythm.

Troubleshooting should begin with checking and tightening all fasteners, ensuring the machine frame remains rigid. A technician should inspect the motor balance and service any worn bearings contributing to instability. When working with especially dense materials, operators may need to reduce speed and fine-tune pressure settings to maintain smooth, stable operation.

9. Honeycomb Cell Collapse or Internal Core Damage

Sometimes the cut appears clean externally, but the honeycomb panel suffers internal cell collapse or hidden core damage. This usually happens when cutting pressure is too high, crushing the internal cell walls without visibly affecting the edges. Another major factor is using the wrong die type, particularly dies with blunt or wide blade angles. Incorrect feeding orientation also causes core damage, as honeycomb board has a grain direction and reacts differently depending on the angle of applied pressure.

To prevent internal collapse, operators should use the minimum effective pressure required for a clean cut. Switching to honeycomb-specific dies helps ensure the blade slices the cells rather than crushing them. Finally, always verify the grain direction of the material and align it correctly before feeding, especially for structural or load-bearing applications.

Troubleshooting Checklist for Honeycomb Die Cutting Machines

Implement a regular maintenance schedule to catch problems early.

• Daily Inspection: Check for loose bolts, inspect blade sharpness visually, clean visible dust, and listen for unusual noises.

• Weekly Maintenance: Lubricate all recommended points, clean dust extraction filters, and inspect ejection foam for wear.

• Blade/Die Replacement Schedule: Track the usage of each die and establish a schedule for sharpening or replacement based on performance, not just failure.

• Operator Skill Checklist: Ensure operators are trained to recognize signs of poor cut quality and know how to make basic adjustments to pressure and speed.

How to Prevent Problems Before They Occur

Proactive measures are always more cost-effective than reactive repairs.

Proper Machine Setup: Calibrate your machine precisely for the specific honeycomb material you are cutting. Don’t use a one-size-fits-all approach.

Select the Right Die: Invest in high-quality, sharp dies designed specifically for honeycomb materials. The right tool makes all the difference.

Match Pressure to Material: Test different pressure settings to find the sweet spot that cuts cleanly without crushing.

Add Dust Extraction & Cooling: These systems are not optional luxuries; they are essential for maintaining machine health and product quality.

When to Repair vs. When to Replace

Knowing when to invest in a new machine can be a tough decision.

• Warning Signs of Major Failure: If you experience frequent, recurring breakdowns, see cracks in the machine frame, or find that replacement parts are obsolete, it may be time to replace.

• Cost-Benefit Analysis: Compare the escalating costs of repairs and downtime against the ROI of a new machine. A new machine can offer greater efficiency, better automation, and higher-quality output that quickly pays for itself.

• Upgrade Options: Modern machines often come with advanced features like servo-driven controls, automated setup, and better diagnostic systems that can significantly improve productivity and reduce troubleshooting time.

FAQs

How long does a die typically last when cutting honeycomb board?

This varies greatly depending on the blade material (e.g., D2 steel vs. tungsten carbide), the abrasiveness of the honeycomb board, and the total cutting volume. With regular maintenance, a high-quality steel-rule die might last for tens of thousands of impressions, but it will require sharpening multiple times during its lifespan.

Can one machine cut different honeycomb thicknesses?

Yes, most machines are adjustable. However, you will need to re-calibrate the cutting pressure, die height, and ejection system for each thickness to ensure optimal results.

What’s the best blade steel grade for heavy-duty honeycomb?

For high-volume cutting of abrasive honeycomb, high-speed steel (HSS) or tungsten carbide blades offer superior durability and wear resistance compared to standard D2 tool steel.

Does humidity affect cutting performance?

Yes. High humidity can soften the paper fibers, making the board more prone to tearing and creating fuzzy edges. Storing honeycomb board in a climate-controlled environment helps ensure consistent cutting performance.

What safety steps should operators follow before troubleshooting?

Always follow lock-out/tag-out (LOTO) procedures. Disconnect the machine from its power source before performing any maintenance, cleaning, or blade adjustments to prevent accidental activation.

Your Path to Better Cutting

Achieving a perfect cut on honeycomb paperboard is a science. The most common faults—from incomplete cuts to crushed edges—are almost always linked to incorrect pressure, dull blades, or improper machine setup. By understanding the unique properties of honeycomb material and implementing the troubleshooting steps and preventive maintenance routines outlined in this guide, you can dramatically improve your operational efficiency, reduce material waste, and minimize costly downtime. Regular maintenance and a well-trained team are your best defense against production interruptions.

WUXI SHENXI

At Wuxi Shenxi Honeycomb Machinery Factory, we bring over 20 years of expertise in honeycomb equipment manufacturing to help you achieve reliable, high-precision cutting. If you need professional guidance or want to upgrade your production line, our engineers are ready to assist