Force Transfer
Forming tools used in the embossing process consist of two matching parts that sandwich the substrate. The male counter die is the raised relief component, usually made of a hard plastic or composite material, that fits into the recessed areas of the female die. It is mounted on the opposite side of the press to push the paperboard into the design.
This mechanical action stretches the fibers to create a three dimensional effect on the surface of the board.
Geometry Matching
Precision is required when aligning the male counter die with its female counterpart to avoid shearing the paper. The counter must be slightly smaller than the female cavity to allow for the thickness of the board. This gap, known as the clearance, determines how sharp the edges of the emboss will appear.
If the counter is too large, it will burst through the fibers and ruin the carton.
Sheet Support
Consistency in production depends on the durability of the counter material. Harder counters provide a sharper image but can be more difficult to set up. Modern versions are often cast from a liquid resin directly against the female die to ensure an exact fit.
This custom fit provides the even pressure needed to prevent wrinkling in the surrounding areas of the sheet.
