Method and system for applying an adaptive perforation cut to a substrate

A package definition system, comprising:

• a data storage facility containing a package design file;
• a processor;
• and a computer-readable medium containing programming instructions that, when executed, instruct the processor to:
• select, from the data storage facility, a package design file comprising a two-dimensional representation of a three-dimensional structure having a plurality of facets;
• identify an edge between two facets to which a perforation line is to be applied, the perforation line comprising a plurality of cut segments and a plurality of spacers;
• determine a length of the edge;
• determine an aspect ratio of a default cut segment length to spacer length;
• use the length of the edge and the aspect ration to determine a number of cut segments that will be included in the perforation line;
• if the number of cut segments is not an integer, determine an integer number of cut segments by rounding the number of cut segments up or down, setting the number of cut segments to equal the integer number of cut segments, and determining a revised cut segment length based on the number of cut segments the edge length;
• and update the package design file to include data indicating that the perforation line will include the integer number of cut segments and the revised cut segment length.

A method comprising, by a processor:

• accessing a package design file comprising a two-dimensional representation of a three-dimensional structure having a plurality of facets;
• identifying an edge between two facets to which a perforation line is to be applied, the perforation line comprising a plurality of cut segments and a plurality of spacers;
• determining a length of the edge;
• determining an aspect ratio of a default cut segment length to spacer length;
• using the length of the edge and the aspect ratio to determine a number of cut segments that will be included in the perforation line;
• if the number of cut segments is not an integer, determining an integer number of cut segments by rounding the number of cut segments up or down to equal an even or odd integer based on whether the edge will be a crease or a perforation line, selecting an even or odd integer based setting the number of cut segments to equal the integer number, and determining a revised cut segment length by:
• determining that the integer number of cut segments at the default cut segment length will result in a perforation line length that exceeds the length of the edge, and
• in response, implementing a reduction process comprising reducing the cut segment length of at least one of the cut segments, a length of at least one of the spacers, or both;
• and updating the package design file to include data indicating that the perforation line will include the integer number of cut segments and the revised cut segment length.