Score die, score die forming system, and associated method

A method of forming a score die comprising:

• providing a number of blanks;
• forming a soft finished score blade on each blank;
• heat treating each soft finished score blade to change each soft finished score blade into a hard finished score blade on each blank;
• machining each said hard finished score blade to change a shape of each hard finished score blade into a substantially finished score blade on each blank;
• and
• performing a number of finishing operations on each said blank with said substantially finished score blade,
• wherein each substantially finished score blade includes a number of cutting portions,
• wherein each cutting portion includes a first surface, a second surface, and a flat vertex,
• wherein the flat vertex extends from the first surface to the second surface,
• wherein a thickness of each cutting portion at the flat vertex does not change by more than 10% along a length of the cutting portion,
• wherein a height of each cutting portion does not change by more than 10% along the length of the cutting portion,
• wherein an angle between the first surface and the second surface of each cutting portion does not change by more than 10% along the length of the cutting portion, and
• wherein the angle between the first surface and the second surface is substantially 25°, and wherein the flat vertex has a length of between 0.001 inch and 0.0015 inch.