To ensure a successful converting process, converters must utilize the newest dies and diecutting capabilities. With the advancement of technology, dies can accomplish more than ever before. From intricate designs to multi-layer constructions, Wilson Manufacturing has engineered solutions to meet the widest range of needs.

To learn more about diecutting and the newest products on the market today, L&NW sat down with Joe Fischer, technical manager, Wilson Manufacturing.

L&NW: What trends is Wilson Manufacturing seeing with dies and the diecutting process?
JF: At Wilson Manufacturing, we’re seeing a strong shift toward higher efficiency, tighter tolerances, and tooling engineered for extended performance in high-speed and high-volume applications. The push for thinner substrates and more sustainable materials has driven innovation in die design, coatings, and material compatibility. There’s also increasing demand for dies that can handle intricate designs and multi-layer constructions, particularly in the medical, electronics, and high-end label markets. Additionally, customers are looking for tooling that integrates seamlessly with automated systems and supports shorter changeover times.

Emphasis on sustainable diecutting practices and materials continues to grow. This includes eco-friendly substrates and a focus on minimizing waste with customers looking for die solutions that can handle recyclable materials effectively too.

L&NW: How has the diecutting process evolved in recent years?
JF: The diecutting process has evolved significantly due to advancements in both materials and machinery. We’ve moved from purely mechanical setups to more data-driven, digitally calibrated systems. Tighter registration, higher line speeds, and more stringent quality control standards mean dies must be engineered with more precision than ever before.

At Wilson, we’ve adapted by investing in customized, advanced CNC machining, quality raw materials, and proprietary hardening and coating processes that enhance longevity and consistency. Customization is now the norm—dies are no longer just tools; they’re critical components of an optimized converting system.

L&NW: What are some of the most common challenges customers come to you with?
JF: The most frequent challenges include premature die wear, difficulty cutting through specific materials, and a need for consistent performance across different press platforms. We also see customers struggling with increased downtime due to tooling-related issues although the root problem often isn’t the die itself but a mismatch between the tooling and the application. That’s why we work closely with converters to diagnose the full scope of the challenge and provide targeted, often custom-engineered solutions.

L&NW: How does Wilson serve as a partner to customers in ensuring they get the right dies for their applications?
JF: We approach every customer engagement as a partnership. From the first contact, we work to understand the customer’s materials, press configuration, production goals, and operational pain points. We provide in-depth technical support, on-site care and handling, training, as well as tooling audits.

Our manufacturing process is built for flexibility, enabling us to design and produce highly specialized dies with fast lead times. Our goal is always to ensure our tooling not only fits but enhances the customer’s overall process, reducing waste and downtime while increasing output.

L&NW: What are some of Wilson’s newest products?
JF: Among our latest innovations is our Extreme enhancement for our S100 and A100 steels to offer even greater durability and performance in demanding applications. We’ve also launched advanced adjustable anvil systems, which allow for micro-adjustments on-press to compensate for material variation, as well as extend die life. Additionally, our line of flex dies for digital converting continues to grow, meeting the rising demand from short-run, quick-turn environments without compromising on cut quality.

L&NW: What other services does Wilson offer customers to improve their experience?
JF: Beyond tooling manufacturing, Wilson offers a comprehensive suite of value-added services, including tool reconditioning, on-site technical support, custom coatings, and solution-based accessories. We also provide press-side training and troubleshooting support to help operators get the most out of their tooling. Our online ordering portal and dedicated customer service team ensure seamless quoting, ordering, and tracking. Everything we do is designed to maximize uptime, performance, and return on investment for our customers.