Plotter knives when to replace FAQ

To help understand the knives for the plotter, we will discuss some of the differences. 
We’re also talking about knives and needles; two other terms for plotter blades. Whether you call them blades, knives or needles.

FAQ's

1. Are blades interchangeable from one brand of cutter to another?
2. How much of the blade tip should be exposed? 
3. What blade angle should you use for different types of vinyl?  
4. How often should it be replaced? 

Answers -
1A - 

Generally speaking, vinyl cutter blades are not universally compatible. The blade has to fit in the blade holder and the blade holder has to fit snugly in the tool carriage. So whether you’re purchasing a new blade or blade holder, you have to  make sure it’s compatible with the brand of cutter you’re using.  EnduraBlades fit a fairly wide variety of cutters including Vinyl Express R Series, EnduraCUT series, Vinyl Express Bobcat, Lynx, and Panther cutters, and all Roland plotters.

2A- 

If you have enough blade sticking out to clearly see and feel the tip, it’s probably too far out.  Most new vinyl cutter owners improperly install the blade with too much of it protruding from the holder. Set it so that you can barely see the tip. Then take the blade holder and manually drag it across a sheet of vinyl making a box pattern or square. You should be able to weed that easily, but you shouldn’t see deep scoring of the release liner. If you flip the vinyl over, you should not be able to feel the cut line in the back of the liner. If you can cut vinyl manually without carving up the liner, you’ve gotten it right.

3A - 

Here’s the BIG question. Which blade should you use for which vinyl? The three most commonly used plotter blade angles are 30, 45, and 60 degrees. Many manufacturers only use 45 and 60 degree blades.  Time for a little geometry refresher. The angles are referred to in terms of degrees because the cutting depth is determined by the angle of the intersection of the cutting edge and the shaft. For standard sized graphics in most calendared PVC vinyl's, a standard 45° blade works fine, if correctly installed. f you have a 30° blade option, use that for standard sized graphics in thin films like cast vinyl and ORACAL’s delicate 1mil 352 chrome. For standard sized graphics in thicker or tougher films like retro-reflective film, sand blast stencil, or flock,  a 60° blade is recommended because it cuts more deeply into the film. All of these fit in the same blade holder. The only difference is the angle of the tip.

4A.- 

When to replace? When you begin to have problems weeding your vinyl, or if you see visible degradation of cut quality, inspect the blade. Look for chips along the cutting edge. Sometimes the damage is obvious, sometimes not. If it looks good but works poorly, try a new blade and see if quality improves. Obviously, you’ll need to keep some on hand, so you can do this and replace as necessary.

How long does a normal blade last? There’s not a standard lifespan for plotter blades. As the EPA says, your mileage may vary. It depends on how much vinyl you cut, and what kind of materials you cut. The glass beads and metal flake used in reflective and metallic films dull blades more quickly than standard PVC vinyl’s. And, as noted above, how precisely you set your blade for the materials you cut affects its service life.

Don’t cut too deeply. Paper dulls blades faster than anything. Cutting too deeply into paper release liners can accelerate normal wear, dulling the tip and making weeding more difficult.

What about maintenance? Plotter blade maintenance is simple. Keep it clean. A buildup of vinyl debris inside the blade holder can interfere with proper rotation of the blade and degrade cutting quality. Inspect the blade holder periodically and remove any debris.

Hope this helps with your knife questions for your plotter/cutter.