Method of setting up a machine for die cutting

A method of setting up a machine for die cutting to reduce the wear of cutting knives of the die-cutting machine, the die cutting machine having a top chase section having a bottom surface, and a bottom machine bed section having a top cutting surface, the method comprising the steps of:

• a. Attaching a number of layers of different materials to the bottom surface of the top chase section in the following order;
• i. a plurality of depth providing layers ranging from 0 to 200 layers, wherein the number of layers used is determined by the number of layers necessary for the top chase section to make adequate contact with the top cutting surface of the bottom machine bed section of the die-cutting machine when the top chase section is depressed,
• ii. a solid material layer, and
• iii. a first non-stick material layer over the solid material layer;
• b. Attaching both a malleable material layer capable of receiving a set of impressions of top cutting surface imperfections and a second non-stick material layer over the malleable material layer to the top cutting surface of the bottom machine bed section;
• c. Depressing the top chase section onto the bottom machine bed section with sufficient force as to leave the set of impressions of the top cutting surface imperfections in the malleable material layer;
• d. Raising the top chase section;
• e. Removing the malleable material layer from the bottom machine bed section so as to not disturb the impressions of the top cutting surface imperfections in the malleable material layer;
• f. Adding additional malleable material to the top cutting surface of the bottom machine bed section as needed to make a side of the malleable material not carrying the impressions one level plane;
• g. Hardening the malleable material layer by a hardening process, thereby finishing a backplate footprint;
• h. Placing and sealing the backplate footprint into the top chase section positioned over the top cutting surface so that the impressions of the top cutting surface imperfections face downward into the lower layers of the top chase section, thereby forcing the lower layers to be warped to a shape of the impressions thereby causing the cutting knives in the die to change their position to more closely align the cutting knives to match the imperfections of the top cutting surface.