Q: What happens to the scrap slug after a cut is made?

One of the biggest advantages of Soft Punch tools is the management of the scrap “slug”, or “chad”. The slug is securely pushed up into the blade cavity during the cutting process. It will not fall out or become dislodged until the Operator safely removes it using the provided scrap removal tool. For small punches, this is done with a thin silicone sheathed metal probe. For larger tools, a suitable pair of needle-nose pliers is quite effective.

Q: How many hole cuts can be made before pausing to remove the film slugs?

This is highly application dependent. It is common for users of the tools to “over-punch” a great number of holes, while forgetting to remove the film slugs. Fortunately, for larger hole cuts (>1”) this is rarely a problem. However, it becomes more difficult for smaller film slugs should the column of slugs inside the blade become compressed. The thickness, stiffness, and media type must be considered. It is recommended that a few tests are conducted whereby Operators and Managers can agree on a procedure for the frequency of slug removal depending on hole cut size and the material.

Question 1

Are Soft Punch tools cleanroom compatible?

Accepted Answer

The Standard Soft Punch tool in hole cut diameters up to 1.5” (38.1mm) is machined from TSE/BSE compliant Delrin with a precision surface roughness of 1.6um to ensure cleanability. Larger hole cutting tools are made from a combination of Delrin and 3D printed material. Customers may need to evaluate the suitability of larger tools for cleanroom use depending on the application. Contact Canopy for more information.

Question 2

What materials can Soft Punch cut?

Accepted Answer

Soft Punch tools were designed for cutting a wide range of plastic films and other flexible materials, such as paper and thin metal foils. Soft Punch tools perform very well on thin materials (<0.001”) where other types of impact tools, punches and circular cutters struggle.

Question 3

What happens to the scrap slug after a cut is made?

Accepted Answer

One of the biggest advantages of Soft Punch tools is the management of the scrap “slug”, or “chad”. The slug is securely pushed up into the blade cavity during the cutting process. It will not fall out or become dislodged until the Operator safely removes it using the provided scrap removal tool. For small punches, this is done with a thin silicone sheathed metal probe. For larger tools, a suitable pair of needle-nose pliers is quite effective.

Question 4

How many hole cuts can be made before pausing to remove the film slugs?

Accepted Answer

This is highly application dependent. It is common for users of the tools to “over-punch” a great number of holes, while forgetting to remove the film slugs. Fortunately, for larger hole cuts (>1”) this is rarely a problem. However, it becomes more difficult for smaller film slugs should the column of slugs inside the blade become compressed. The thickness, stiffness, and media type must be considered. It is recommended that a few tests are conducted whereby Operators and Managers can agree on a procedure for the frequency of slug removal depending on hole cut size and the material.

Question 5

What hole sizes are available?

Accepted Answer

Standard Soft Punch sizes cover hole diameters ranging from 0.25" to 5.00”. Please refer to the product pages for tool sizes, part numbers and prices. Custom sized holes and shapes (curves, ovals, slits and hanger holes) are available upon request.

Question 6

Why not just use a hammer-driven Arch Punch?

Accepted Answer

Arch punch tools remain a common tool for creating holes in a variety of materials.  However issues such as:
Operator safety
Particle generation on impact
Reproducibility
Cut quality 
These issues create challenges for using Arch Punches in certain critical applications and manufacturing environments, such as cleanroom production areas.

Question 7

Why use Soft Punch instead of a high-volume CNC-controlled laser cutting system?

Accepted Answer

Soft Punch is designed for low-to-medium volume production (10,000 to 100,000+ hole cuts per year). These volumes are typical in prototyping areas and for custom assembly work. Automated laser cutting systems have much higher capacity and could be overkill, unable to fabricate highly customized jobs, or simply cost prohibitive.

Question 8

Does Soft Punch require electricity or compressed air?

Accepted Answer

No. Soft Punch is a completely manual system and requires no external power source.

Question 9

Can Soft Punch be used for custom bag modifications?

Accepted Answer

Absolutely. Soft Punch is commonly used for creating openings for ports, tubing, fittings, and other custom modifications in single-use process assemblies and bioprocess bags.

Question 10

Is operator training required?

Accepted Answer

Minimal training is required. Most operators can become proficient with Soft Punch after a brief demonstration and review of the operating instructions.

Question 11

What maintenance is required?

Accepted Answer

Soft Punch requires minimal maintenance. Routine cleaning, inspection of cutting components, and periodic blade replacement will ensure optimal performance. It is always recommended to review the cut quality of the hole at the beginning and ending of a shift.

Question 12

Can replacement blades be purchased separately?

Accepted Answer

Yes. Replacement blades and other consumable components are available to help maximize tool life and minimize downtime. Blades can be easily changed on-site by following instructions in the user manual.

Question 13

Can Soft Punch damage the film being cut?

Accepted Answer

When used properly, Soft Punch is designed to produce clean, repeatable holes with minimal material distortion.

Canopy Design Group

Innovative Tooling & Solutions for Hole Cutting Applications

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