XP Tooling Guide

The XP tooling system

Tool units for heavy duty tool position

The Heavy-Duty Tool Unit tool pack
The Foam Cutting Unit tool pack
The High-Speed Milling Unit tool pack

Tool Units for the fast tool position

The VibraCut Knife Tool
The High-frequency VibraCut Knife Tool
The HiForce Knife tool
The Rigid Material Knife tool
The PressCut Tool
The RotaCut Tool

Tools for the insert position

Tool inserts for the Heavy-Duty Tool Unit

Knife blades for the XP Series

Blades for V-notch and HD-knife
Blades for the VibraCut and HF VibraCut knife tool
Blades for the Rigid Material knife tool
Blades for the HiForce knife tool
Blades for the Foam Cutting Unit

Crease tools
Crease profiles for XP tools
Crease wheel profiles the Heavy-Duty Tool Unit
Crease Blades

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 The XP tooling system
The XP tooling system consists of a wide variety of optional tool units. These can be quickly mounted in
the tool position accommodated for the tool and prepared to cut and finish a specific job, assuring
exceptional quality and prompt delivery. Three tool positions are available, enabling usage of three tools
within the same job.
Tool position 1 is for heavy tools optimised for power while position 2 is for a set of knife tools optimised
for fast movements. There is also an optional third tool position that accommodates inserts for either
pen plotting or drilling of holes. In addition, the tooling system includes a material thickness probe and
an optional camera for registering to printed images. The layout is as follows:
1. Heavy-duty (HD) tool position
2. Fast tool position
3. Insert position (optional)

1 2 3
Heavy-Duty Tool Unit x
High-Speed Milling Unit x 1
Foam Cutting Unit x 3
High-frequency VibraCut Tool x
VibraCut Tool x
2
Hi-Force Knife Tool x
RM Knife Tool x
PressCut Tool x
RotaCut Tool x
Drill Tool Insert x
Ballpoint Pen Insert x

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 Tool units for heavy duty tool position (pos. 1)

Tool unit

The Heavy-Duty Tool Unit tool pack

Sales code: 97AR5025

This tool unit is mounted in the heavy duty tool position on the XP and is
capable of a down-pressure equivalent to 50kg – 110lbs; sufficient to crease
triple and double-wall corrugated with heavy liners, when configured with the
large-size crease wheels with 150mm – 6” diameter. The large-size wheels
also provide superior crease quality with recycled corrugated board, since a
higher pressure can be applied without cracking the liner.
The HDU comes with a powerful head-rotation mechanism, required to
accommodate the various v-notch adapters and HD knife tools that have
been developed for triple-wall corrugated and other strong and rigid
paperboard constructions. These tools are optional (not included).

Included tooling:
• Three 150 mm (6” ) crease wheels; a 4-point, a 6-point and a V-shaped wheel for triple wall.
• Crease adapter for 26 mm (1”) diameter wheels, plus a 3point and a 6point / 26mm crease wheel.

150mm crease
Crease adapter for 26mm wheels wheel

The Foam Cutting Unit tool pack

Sales code: 97AR5027

The Foam Cutting Unit is mounted in the heavy duty tool position on the XP. It
features a reciprocating knife blade, which permits foam material up to 50mm
(2”) in thickness to be cut.
Two different adapters are included, one for the SR63xx series of blades for
cutting up to 30mm (1 ¼”) material thickness, another for the SR65xx series of
blades up to 55mm (2 ¼”) thickness. Two blades of each type (see picture) are
also included.

The SR6313 blade The SR6523 blade

Appropriate blades: 50, 51, 52, 53, 54, 55

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 The High-Speed Milling Unit tool pack

Sales code: 97AR5026

This tool unit is mounted in the heavy duty tool position of the XP.
The included spindle features a true 1kW of milling power, and adjustable spindle
speeds up to 60,000 RPM. It allows for milling, contour cutting, routing, drilling
and engraving directly from CAD/graphics designs. Materials with thickness up to
50mm (2”) can be milled. (Note: 50mm thickness is only applicable with certain
bits and for certain, light materials.)
Matched with heavy-duty construction and the sophisticated Z-axis control of the
XP tables, the router delivers high quality output at an impressive throughput rate
– making the High-Speed Milling Unit a great tool for real production work.
The milling tool comes with a function to safeguard the spindle towards
unbalanced bits run at too high RPM settings. It also features a switch operated
chuck for fast and tool-free bit exchange, and in combination with the automatic
tool measurement feature milling bit exchange is really safe and efficient.
Due to the high acceleration of the XP the milling tool comes with a free-standing
gallows for carrying the chip suction hose and the electrical cables for the milling
spindle. In order to reach all over the table the XP gallows needs to be quite
high, up to 3m – 9’10” – for the XP46, somewhat lower for the XP24/44.

Milling bit starter kit:

Included with the High-Speed Milling Unit is a set of milling bits:

• 1x Acrylic, single flute, 3 mm tip, 11 mm flute length (BIT-AUS06-3011-50)
• 1x Acrylic, single flute, 5 mm tip, 22 mm flute length (BIT-AUS06-5022-58)
• 1x Multi-purpose, 3 mm tip, 11 mm flute length (BIT-MUS06-3011-50)
• 1x Multi-purpose, 5 mm tip, 22 mm flute length (BIT-MUS06-5022-58)

The milling spindle comes with a Ø6mm collet as standard. Optionally available are ¼’ and 3mm collets.

Milling underlays

Included with the High-Speed Milling Unit is a set of milling underlays made of hard pressed felt. Section sizes
and numbers as per the table below. The felt underlay is about 3mm thick and is placed on top of the standard
PVC cutting mat.

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 Tool Units for the fast tool position (pos. 2)

The VibraCut Knife Tool

Reciprocating knife tool suitable for corrugated board and other light-duty fibrous materials. An internal
electrical motor provides knife reciprocation.
To reduce material tear and also to keep the material down as the knife is pulled out, a detachable
plastic cup is included
Different knife adapters allow for different knife types.
The tool has to be removed from the Z-carriage for knife blade replacement.
Maximum cutting thickness is 10mm – 3/8”.

Appropriate blades: #14, 15, 16, 17, 18, 19 with VHM adapter, 30, 31 with SF216/217 adapter.
For knife blade descriptions, see own section in this document.

Sales codes:
97AR909 VibraCut Knife Tool, including 1x SR6223 and 1x SR6224 knife blades
97AR931 Separate knife blade adapter for SF216 and SF217, including 1x SF216 and 1x SF217 blades

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 The High-frequency VibraCut Knife Tool

Special variant of the reciprocating knife tool for cutting a lot of different materials, such as foamboard,
and corrugated with high recycled content.
It runs at twice the frequency and four times the amplitude of the standard VibraCut knife tool. These
properties, along with a more powerful motor, enable cutting of heavily recycled board at efficient speed.
To reduce material tear and also to keep the material down as the knife is pulled out, a detachable
plastic cup is included.
Different knife adapters allow for different knife types.
The tool has to be removed from the Z-carriage for knife blade replacement.
Maximum cutting thickness is blade dependant:
Max 20mm – 3/4” with the short foot,
Max 30mm – 1 1/4 ” with the long foot.

Appropriate blades: 14, 15, 16, 17, 18, 19, 50, 51, 52 with VHM adapter, 30, 31 with SF216/217
adapter. Note: Cutting with blade 50, 51 and 52 requires a longer plastic foot.
For knife blade descriptions, see own section in this document.

Sales codes:
97AR5147 Hi Frequency VibraCut Knife Tool, including 1x SR6223, 1x SR6224, 1x SR6310 and
1xSR6303 blades
97AR931 Separate knife blade adapter for SF216 and SF217, including 1x SF216 and 1x SF217 blades
97AR5148 Long plastic foot for SR6xxx blades

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 The HiForce Knife tool

The Hi-Force knife tool is a general purpose knife tool suitable for cutting a wide range of flexible and
rigid materials. Different knife adapters allow for different knife types.
To reduce material tear and also to keep the material down as the knife is pulled out, a foot is available.
The knife blade is centered (lag = 0).

Appropriate blades: 26, 27, 30, 31, 32, 33, and 34 depending on adapter, see below. For knife blade
descriptions, see own section in this document.

Sales codes:
97AR5028 HiForce Knife Tool including 2x SF216 and 2x SF217 blade.
97AR452 Separate knife blade adapter for half length SF112/113 including 1x SF112 and 1x SF113
blade.
97AR5011 Separate blade adapter for the SR61xx-series

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 The Rigid Material Knife tool

The RM Knife extends the capabilities for knife cutting of rigid materials. The knife blades and tool are
designed such as the blades with cylindrical 8mm shaft are mounted directly in the tool body.

This design gives the tool excellent performance when cutting in rigid materials such as display carton,
rigid plastics such as Forex and polypropylene as well as many qualities of gasket materials.

Appropriate blades: 21, 22, 23. For knife blade descriptions, see own section in this document.
Maximum cutting depth is 4mm for the 80º angle and 6mm for the 60º angle
Sales code:
97AR5029 Rigid Material Knife tool including 2 x DR8160 and 2 x DR8180 knife blades

The PressCut Knife Tool

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 An internal motor provides fast-response tool up/down and exact tool pressure control.
Maximum downward knife pressure is 10N. There is a software function to provide speed
dependent tool pressure control, which is important to ensure reliable cutting when
velocity ramps up and down.
Tool pressure can be changed between different line types, to switch between kisscutting
and through cutting of vinyl foils. For through cutting best results are usually achieved
when the included depth-stop piece is applied.
Maximum tool lift is 4 mm. The knife blade is centered (lag = 0).
The knife pressure level is measured and adjusted automatically; the PressCut tool will
not do a height calibration on the measuring station.
Applicable knife blades: KC101, KC102.
Sales code:
97AR904 PressCut Knife tool, incl. 1x KC101 and 1x KC102 knife blades

The RotaCut knife tool

The RotaCut Tool is specifically developed for

cutting printed textiles such as banners and
flags. Since most textiles are more or less air
transparent the vacuum hold-down system of
the table will not be effective when cutting
such materials. The RotaCut Tool has been
designed with this in mind. It operates by
rotating a 10-facetted knife blade at high
speed, and the blade protrudes from a slot in a hold-down foot that presses down on the
material. The foot is made from a material that reduces friction to a minimum, and these
properties, in connection with the fibrous surface of the conveyor belt, or felt mats,
provides a hold-down sufficient for cutting most textile materials.
Due to the geometric of the 10-facetted knife blade, height adjustment of the RotaCut tool
has to be done manually. Not by the measuring station.

Applicable knife blade: RC110 decagonal knife blade

97AR5050 XP/XE RotaCut Tool, incl. 2 x RC110 decagonal knife blades and
tools for blade change.

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 Tools for the insert position (pos. 3)
The Tool Insert Fixture The optional Tool Insert Fixture is a
prerequisite for mounting tool inserts such as
Sales code: 97AR5030 the Ballpoint Pen Tool and the Power Drill
Tool. These inserts are also optional.

The Ballpoint Pen Insert The Ballpoint Pen Insert option mounts into
the Tool Insert Fixture. NOTE! This fixture is
Sales code: 97AR5031 an option.
Two pen refills; Black, Medium line weight,
are included.

The Drill Tool Insert The drill tool Insert option mounts into the
Tool Insert Fixture. NOTE! This fixture is an
Sales code: 97AR5032 option.
The drill tool is aimed at light-duty drilling in
materials such as RE-board, X-Board and
triple wall corrugated. This tool has a 70W
geared motor and spins with approximately
1000 rpm.
The adjustable chuck accepts drillbits ranging
from 0.5 – 6.5mm, or 1/64” – ¼”.
Two 3mm and two 4mm drillbits are included

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 Tool inserts for the Heavy-Duty Tool Unit in pos. 1

Knife Tool Description

HD17 Knife Tool Heavy-duty knife tool used for rigid board such as RE-board
and triple wall material. Limited to straight lines longer than
Sales code: 97AR379 50mm (2”).
Knife lag: Max. cutting thickness is 17mm.
10.0mm Sold as a kit including five appropriate blades (#41)
Appropriate blades: 41, 42, 43, 44. For knife blade
descriptions, see own section in this document.

HD30 Knife Tool Similar to the above knife but permits cutting of max. 30mm –
1.18” material thickness.
Sales code: Uses a specially designed, Tungsten Carbide knife blade.
97AR725
Will also cut 22mm materials nicely, due to the very rigid
Knife lag: knife blade.
10.0mm
Sold as a kit including two appropriate blades (#13)

Appropriate blades: 13. For knife blade descriptions, see

own section in this document.
V-notch knife tool – 15mm For 45° V-notch cutting in TW corrugated, corrugated plastic
and RE-board. . Its application is to make a 90° partially cut
Sales code: 97AR620 V-notch for folding functionality or a throughcut leaving a
slanted cutting edge.
Max. cutting depth is 15mm - .590”. Limited to straight lines
only.
Sold as a kit including five appropriate blades (#41).

Appropriate blades: 41, 42, 43, 44. For knife blade

descriptions, see own section in this document.
V-notch knife tool – 10mm Similar to the above knife but limited to 10mm – 7/8” cutting
depth. Will provide a more accurate cut in thinner material
Sales code: 97AR274 due to the shorter (=more rigid) exposed blade.
Sold as a kit including five appropriate blades (#41).

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 Appropriate blades: 41, 42, 43, 44. For knife blade
descriptions, see own section in this document.

V-notch knife tool – 15 degrees The 15° V-notch cutting in TW corrugated, corrugated plastic
and RE-board.. Its application is to make a 30° partially cut
Sales code 97AR982 V-notch for folding functionality, such as 12-edge polygonal
pillars or a throughcut leaving a slanted cutting edge.
Max. cutting depth is 16 mm - .590”. Limited to straight lines
only.
Included with the tool is a package of five appropriate knife
blades.

Appropriate blades: 41, 42, 43, 44. For knife blade

descriptions, see own section in this document.
V-notch knife tool – 30 degrees The 30° V-notch cutting in TW corrugated, corrugated plastic
and RE-board.. Its application is to make a 60° partially cut
Sales code: 97AR983 V-notch for folding functionality, such as 6-edge polygonal
pillars or a throughcut leaving a slanted cutting edge.
Max. cutting depth is 16 mm - .590”. Limited to straight lines
only.
Included with the tool is a package of five appropriate knife
blades.
Appropriate blades: 41, 42, 43, 44. For knife blade
descriptions, see own section in this document.

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 Knife blades for the XP Series
Blades for V-notch and HD-knife

# Product name Length / Application

Stock # edge
angle

13 BLD-TZ230 Special trapezoid blade for the HD30 knife tool,

designed for RE-board and similar material in
Sales code: g34061218
thickness up to and including 30mm -1.18”.
Tungsten carbide steel material with precision ground
edge.

41 BLD-TZ129 53° Super-trapezoid, deep-edged blade, used with the V-

notch knife and the HD-knife tool.
Sales code: g42435636
This blade is thicker and stiffer than standard
trapezoid blades and will give a more accurate cut.
Thickness 0.9mm - .035”

42 BLD-TZ192 53° Super-trapezoid, deep-edged blade, used with the V-

notch knife and the HD-knife tool.
Sales code: g42424374
This blade is thinner than the Martor blade and will
give very good result used in ReBoard.
Thickness 0.6mm - .024”

43 BLD-TZ511 (trapez.shaped) 53° Trapezoid shaped blade for v-notching.

Very good blade for V-notch cutting in though
Sales code: g42448589
materials such as Re-board, X-board and triple wall
corrugated. Cuts materials up to about 17mm. Made
from a special Tungsten Carbide alloy, to extend
cutting cycles.
Thickness 0.6mm - .024”

44 BLD-TZ512 (trapez.shaped) 53° Very good blade for V-notch and straight cutting with
the HD-knife tool in though materials such as Re-
Sales code: g42448597
board, X-board and triple wall corrugated. Cuts
materials up to about 17mm. Made from a special
Tungsten Carbide alloy, to extend cutting cycles.
Thickness 0.9mm - .035”

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 Blades for the VibraCut and HF VibraCut knife tool

# Product name Length Application

Stock # / edge
angle

14 BLD-SR6223 39mm Long-life knife blade, works well with most grades of
corrugated board. Used in reciprocating knife tools.
Sales code: g42437293 1.535”
Tungsten carbide steel.
24º

15 BLD-SR6224 39mm Similar to SR6223 but has better properties for

recycled board.
Sales code: g42438135 1.535”
Tungsten carbide steel.
24º

16 BLD-SR6310 39mm Gives nice results in thick and rigid paper-based

materials, such as triple wall corrugated and Reboard,
Sales code: g42441626 1.535”
when used with the High-Frequency VibraCut Knife
11° Tool. Max cutting thickness is about 20mm – ¾”

17 BLD-SR6307 39mm Gives less over-cut than the SR6310 but is more
slender and may give a less accurate cut in curves
Sales code: g42441634 1.535”
when cutting heavy board grades.
7°

18 BLD-SR6303 39mm Good blade for 15 and 20mm foamboard in

combination with the High-Frequency Knife Tool
Sales code: g42441642 1.535”
3.5°

19 BLD-SR6315 39mm Has shorter edge than SR6303, SR6307 and

SR6310. At the same time more slender than SR6224
Sales code: g42449504 1.535”
resulting in a good compromise between
24° stability/strength when cutting fine details such as
small arcs and overcuts. Max cutting depth is about
14mm or ½”. Suited for materials such as soft
foamboards (Kapa®) and plastic corrugated

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 Blades for the Rigid Material knife tool

# Product name Length Application

Stock # / edge
angle

21 Knife Blade – BLD-DR8160 2x 30º Knife blade with 8mm sylindrical shaft for use with the
Rigid Material knife tool. Good blade for cutting in
Sales code:g42447235
rigid materials such as different gasket materials,
forex and solid carton board. Can cut up to about 5-
6mm thick materials depending on the material
quality.

22 Knife Blade – BLD-DR8180 2x 40º

Similar to the blade above. The blunter angle reduces
the risk for breaking the blade in tough materials, but
gives more overcut with thicker materials.

Sales code:g42447284
23 Knife Blade – BLD-SR8124 1x24º Knife blade with 8mm sylindrical shaft for use with the
length RM (RigidMaterial) knife tool. Good blade for cutting
Sales code: g42450494
40mm in different plastic corrugated materials. Can cut up to
about 15mm thick materials depending on the
material quality. Nominal lag value is 4mm

Blades for the HiForce knife tool

# Product name Length / Application

Stock # edge
angle

26 BLD-DF112 50mm General-purpose, double-sided, 80º sword knife blade

Sales code: g42444299 for flexible materials. Used for through-cutting of
2”
paper, cardboard, vinyl, thin plastics, styrene, etc.
2x 40º

27 BLD-DF113 50mm General-purpose, double-sided, 60º sword knife blade

Sales code: g42443036 for flexible materials. Used for through-cutting of
2”
paper, cardboard, vinyl, thin plastics, styrene, etc.
2x 30º

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 30 BLD-SF216 25.0mm Single-edge blade for soft flexible materials. Used for
Sales code: g42441212 through-cutting paper, vinyl, etc.
1”
35º

31 BLD-SF217 25.0mm Single-edge blade for soft flexible materials. Used for
Sales code: g42441220 through-cutting paper, vinyl, etc.
1”
The more pointed edge reduces overcuts.
25º
32 BLD-SR6150 g42445494 25mm TC Blade for thinner flexible materials such as folding
0,98” carton, polyester film, leather, vinyl, paper. 30* cutting
angle. Max. Cutting thickness is about 5mm
30º
33 BLD-SR6152 g42445502 25mm TC Blade for thinner flexible materials such as folding
0,98” carton, polyester film, leather, vinyl, paper. 40* cutting
angle. Max. Cutting thickness is about 3mm
40º
34 BLD-SR6160 g42445510 25mm TC Blade for thinner flexible or rigid materials such as
0,98” solid carton, vinyl, plastics. 2x30* cutting angle.
Spear-headed shape. Max. Cutting thickness is about
2*30º 5mm

Blades for the Foam Cutting Unit

50 BLD-SR6311 Blade for max. 30mm material thickness. Fits both Foam Cutting Unit as
well as VibraCut / HighFrequency
VibrCut when used with suitable
Sales code:
SR6xxx-adaptors. 2.5° cutting angle
g42443101
enables very fine details with little over-cut in foam qualities with good cutting
properties. Pointed tip for use with felt underlays.
51 BLD-SR6312 Blade for max. 30mm material thickness. Fits both Foam Cutting Unit as
well as VibraCut / HighFrequency
VibrCut when used with suitable
Sales code:
SR6xxx-adaptors. 6° cutting angle
g42443093
enables fine details in a several different foam qualities. Pointed tip for use
with felt underlays.
52 BLD-SR6313 Blade for max. 30mm material thickness. Fits both Foam Cutting Unit as
well as VibraCut / HighFrequency VibrCut when used with suitable SR6xxx-
adaptors. 8° cutting angle enables fine
Sales code:
details in a wider range of foam
g42443085
qualities, as well as 30mm Re-board.
Flattened tip to increase cutting speed and protect PVC cutting underlays.
53 BLD-SR6521 Blade for max. 55mm material thickness. Fits Foam Cutting Unit with
suitable SR6xxx-adaptor. 2.5° cutting angle enables very fine details with
little over-cut in foam
Sales code:
qualities with good cutting
g42444877
properties. Pointed tip for
use with felt underlays.
54 BLD-SR6522 Blade for max. 55mm material thickness. Fits Foam Cutting Unit with
suitable SR6xxx-adaptor. 3.7° cutting angle enables fine cutting details.
Pointed tip for use with
Sales code:
felt underlays.
g42444885

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 55 BLD-SR6523 Blade for max. 55mm material thickness. Fits Foam Cutting Unit with
suitable SR6xxx-adaptor. 3.7° cutting angle enables fine cutting details.
Flattened tip to increase
Sales code:
cutting speed and protect
g42444893
PVC cutting underlays.

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 Crease tools
Crease profiles for XP tools

An adapter for using crease wheels with diameter 26mm [1”] in the HDU is available as an option. The
application of this adapter is to enable a smaller sized wheel for micro flutes and folding carton.
It will also allow creasing of plastic corrugated with smaller wheels and heavy crease power, which normally
has a good effect on defeating the 'memory' of the plastic material.
The standard Ø26mm crease wheels will fit the adapter, with no need for resetting the height reference when
the adapter replaces the Ø150mm crease wheel.

Crease adapter for Ø26mm wheels

Included in The Heavy-Duty Tool Unit tool
pack

1 point 10 point
Sales code: g32532129 Sales code: g32529091

2 point 12 point
Sales code: g32524837 Sales code: g32529117

3 point 14 point
Sales code: g32529075 Sales code: g32547051

4 point Triple wall

Sales code: g32536542 Sales code: g32537706

6 point R Crush, R=15

Sales code: g32522880 Sales code: g32524811

8 point Double edge, 1 point (0.6 mm spacing) Sales

Sales code: g32529240 code: g32546640

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 Crease wheel profiles the Heavy-Duty Tool Unit

Crease wheel - U-shape, 150mm [6"] diameter.

For double- and triple wall of good quality.
Sales code: g34007096

Crease wheel - V-shape, 150mm [6"] diameter.

For recycled board with brittle liners.
Sales code: g34007906

Crease wheel - 6-point, 150mm [6"] diameter.

For single wall corrugated
Sales code: g34023234

Crease wheel - 4-point, 150mm [6"] diameter.

For solid board (carton), chipboard, etc.
Sales code: g34010306

Crease Blades

For creasing thin, synthetic materials such as polypropylene and polyethylene (PET)
These crease tips scribe into the material and provide a more distinct fold line than a wheel, due to the
smaller impact area. The blades fits the HiForce knife tool with adapter for 212/213 blades (97AR452)

Crease Blade 0,5 mm for HiForce knife tool

Sales code: g42444711

Crease Blade 1,0 mm for HiForce knife tool

Sales code: g42444729

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