i-cut Production Console

Get the best out of iPC

05 - 2020
 i-cut Production Console

Contents
1. Preface......................................................................................................................................................... 5

2. Change Record........................................................................................................................................... 6

3. Welcome...................................................................................................................................................... 7

4. Symbols used............................................................................................................................................. 8

5. Introduction................................................................................................................................................9
5.1. Optimal Workflow............................................................................................................................. 9
5.2. Semi-optimal Workflow.................................................................................................................. 10
5.3. Manual Workflow............................................................................................................................ 10

6. iPC Workflow............................................................................................................................................ 12

7. Manual Job Setup.................................................................................................................................... 18

7.1. Layer settings.................................................................................................................................. 18
7.2. Production settings......................................................................................................................... 20
7.2.1. Copies.................................................................................................................................... 20
7.2.2. Quality....................................................................................................................................21
7.2.3. Material Handling................................................................................................................. 21
7.2.4. Registration............................................................................................................................23
7.2.5. Position.................................................................................................................................. 25
7.2.6. Step and Repeat................................................................................................................... 25
7.2.7. Tool Head Parking................................................................................................................ 25

8. Examples how to run a Job................................................................................................................... 27

8.1. Running a Job with Registration Marks.........................................................................................27
8.2. Running a Job with Barcode.......................................................................................................... 29

9. Production workflows............................................................................................................................ 33
9.1. Workflow 1 - Creating a design for iPC using ArtiosCAD............................................................. 33
9.1.1. File formats and technical line definition........................................................................... 33
9.1.2. Create a file using Run a Standard in ArtiosCAD............................................................... 33
9.1.3. How to use the ArtiosCAD output to iPC........................................................................... 35
9.1.4. How to configure an output from ArtiosCAD to iPC..........................................................37
9.2. Workflow 2 - Creating a design for iPC using Adobe Illustrator..................................................44
9.2.1. File formats and technical line definition........................................................................... 44
9.3. Workflow 3 - Creating a design for iPC using Third Party RIP..................................................... 47
9.3.1. File formats and technical line definition........................................................................... 47
9.4. Workflow 4 - Creating a design for iPC using i-cut Layout.......................................................... 48
9.4.1. File formats and technical line definition........................................................................... 49
9.5. Workflow 5 - Underside Camera (USC) Regmark preparations...................................................54

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9.5.1. Understanding the camera system.....................................................................................54

9.5.2. Registration Marks definition.............................................................................................. 54
9.5.3. Placement of Registration Marks........................................................................................ 54
9.5.4. Preparing Regmarks for USC using SmartMarks in i-cut Layout and Automation
Engine..........................................................................................................................................57
9.5.5. Preparing files manually in Adobe Illustrator.....................................................................59
9.5.6. Preparing USC Regmarks in ArtiocCAD...............................................................................61
9.5.7. Operation with Underside Camera..................................................................................... 62
9.6. Workflow 6 - Design from Digital Flexo Suite to iPC.................................................................... 63
9.6.1. Setting up connection between DFS and iPC.....................................................................64
9.6.2. Import Mapping and Tooling Presets for Flexo..................................................................67
9.6.3. Create flexo materials on iPC.............................................................................................. 71
9.6.4. Apply presets to the flexo materials...................................................................................72
9.6.5. Tips & Tricks.......................................................................................................................... 75
9.7. Workflow 7 - Design from Esko Device Manager to iPC.............................................................. 75
9.7.1. File formats generated from Esko Device Manager...........................................................76
9.7.2. File preparations for Device Manager................................................................................ 76
9.7.3. Export file from Esko Device Manager for further processing..........................................77
9.7.4. Importing files to My Jobs....................................................................................................77
9.8. Workflow 8 - Structural design with graphics to print and cut................................................... 77
9.8.1. Create a structural design “one up” in ArtiosCAD..............................................................78
9.8.2. Add graphics in Adobe Illustrator....................................................................................... 79
9.8.3. Nest job in icut-Layout......................................................................................................... 80

10. Understanding print compensation for soft signage.....................................................................83

11. Appendix 1 - iPC Resources.................................................................................................................88

11.1. Material is Key...............................................................................................................................88
11.2. Resource Manager........................................................................................................................ 88
11.3. Setting up Resources.................................................................................................................... 89
11.3.1. Chain of events when creating a new Job........................................................................ 91
11.4. Job Estimation............................................................................................................................... 92
11.5. Preparing Resources for optimal production............................................................................. 93
11.6. Setting up Tooling Presets........................................................................................................... 93
11.6.1. Use a pre-defined Tooling Preset......................................................................................95
11.6.2. Create new Tooling Presets from a configured job......................................................... 98
11.7. Setting up Optimization Presets................................................................................................101
11.8. Setting up Production Presets................................................................................................... 102
11.9. Setting up Cutting Profiles......................................................................................................... 103
11.10. Setting up My Materials........................................................................................................... 104
11.11. Setting up Material Families.................................................................................................... 106
11.12. Setting up Mapping Presets.....................................................................................................107
11.13. Working with Submit Folder.................................................................................................... 111
11.14. Migration....................................................................................................................................111

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11.14.1. Convert Cutting Keys to Tooling Presets...................................................................... 111

11.14.2. Use i-cut vision Cutting Keys and prepare as Tooling Presets.................................... 113

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1. Preface
Get the best out of

i-cut Production Console

Note: We remind you that only the Esko staff, or persons having received appropriate training,
are allowed to handle, manipulate or do repairs on the system.

©Copyright 2020, Esko-Graphics Kongsberg AS, Norway

All Rights Reserved.

This copyright does not indicate that this work has been published.
This material, information and instructions for use contained herein are the property of Esko-Graphics
Kongsberg AS. There are no warranties granted or extended by this document. Furthermore, Esko-Graphics
Kongsberg AS does not warrant, guarantee or make any representations regarding the use, or the results
of the use of the system or the information contained herein. Esko-Graphics Kongsberg AS shall not be
liable for any direct, indirect, consequential or incidental damages arising out of the use or inability to use
the system or the information contained herein. The information contained herein is subject to change
without notice. Revisions may be issued from time to time to advise of such changes and/or additions.
No part of this system may be reproduced, stored in a data base or retrieval system, or
published, in any form or in any way, electronically, mechanically, by print, photoprint, microfilm
or any other means without prior written permission from Esko-Graphics Kongsberg AS.
This document supersedes all previous dated versions.
Correspondence regarding this publication should be forwarded to:
Global support
Esko-Graphics Kongsberg AS

Document no: D3634

Part no: -

Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, NO-3601 Kongsberg, NORWAY
Tel.: +47 32 28 99 00

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2. Change Record
Date By Description

dd.mm.yyyy

21.06.2019 DHO New edition for iPC 2.3.

New SmartMark for USC.
ArtiosCAD Workflow for USC.
JDF Barcode production now works as any
other file.

22.08.2019 DHO Print compensation for soft signage added

20.11.2019 DHO Misc.
13.05.2020 DHO Updated for iPC 2.4
Workflow 8 added.

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3. Welcome

Welcome to the user manual Get the best out of i-cut Production Console (iPC).
Throughout this manual, the abbreviation iPC is used for i-cut Production Console.

This manual is aimed for operators of Kongsberg Cutting Tables and people preparing files for
such equipment.

Note: Some of the functions described in this manual are license dependant

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4. Symbols used
Operator Panel buttons:

Start

Pause

Set Reference Point

Switch Vacuum On

Move Tool down

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5. Introduction
In iPC, we base the Job Settings on the material that is used for producing the Job.
By focusing on the material, we can optimize tools and apply settings that will give a good
result.

This document describes several Workflows based on the concept of filtering on material.
We call this concept Material is Key.

Material is Key:
1. The Material is defined in the upstream application that creates the design or layout (input
file)
2. The material is configured in iPC and mapped to tools and production settings
3. The design is prepared in a way that can be interpreted by iPC (examples are Layers, Line
Types, Spot Colors)
Given that these three requirements are met, the job is ready for production.

The level of preparations that is done early in the Workflow simplifies the process in the later
stages:
1. Optimal Workflow – File ready from the Designer with no operator intervention required
for setting up the Job in iPC
2. Semi-optimal Workflow – Some operator intervention needed in setting up the job in iPC
3. Manual Workflow – All Job preparations is manual and made by the operator in iPC

5.1. Optimal Workflow

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All steps in the preparation are done in the Create Design phase:
• File created by the designer includes known technical lines and the file format used includes
material information
• Material is configured in iPC Resources

We call it an Optimal Workflow when the Designer has done most of the preparations for
the Job. This will significantly simplify the Operator’s tasks by only open the file and start the
production.

5.2. Semi-optimal Workflow

All steps in the preparation are done in the Create Design and Add File phase.
• File created by the designer includes known technical lines, but the file format used has no
possibility to include material information
• Material is pre-prepared in iPC Resources

In the “Semi-Optimal workflow”, the operator selects, in iPC, the necessary Presets to make
the Job ready for production.

5.3. Manual Workflow

In the manual Workflow, the operator needs to update all settings for the job.
• File to be executed is not fully prepared
• iPC setup is not completed

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• Opened is not ready for production and needs full preparation in iPC before producing
You find how to prepare your job in Manual Job Setup on page 18.

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6. iPC Workflow
This section gives you the general guidelines on how the iPC Workflow is applied.
If you follow these guidelines, and prepare your Input File and configure iPC settings, you will
be able to open and run the Job with minimal operator interaction.

Step 1 – Create Design

1. Prepare Job with technical lines such as Cut, Crease, Regmark, KissCut etc.
The technical lines are translated into Layers with dedicated Layer Types in iPC. Layer Types
is used to apply correct Tool Settings from the Tooling Preset.

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Note:
If you are using customized line names, you have to add this to your Mapping Presets,
otherwise the Layer Type will be unknown. See section Setting up Mapping Presets

2. Save into two seperate files:

• Print file (Including graphics and Registration Marks)
• Cut file (Including technical lines and Registration Marks)
It is recommended to use a File Format that also can include Metadata; e.g Material, this
will give the most Optimized Workflow, where operator can run the job without any setup
interaction.
File formats supported by iPC
1. JDF Files (Includes material and Barcode information)
2. Native ArtiosCAD (ARD/MFG) files
3. SCRIPT Files
4. ACM Files
5. PDF files (no metadata included)

Step 2 – Add file to iPC

Add Jobs to iPC:

• Manually
• Submit folder ("Drop folder")
• Device Manager submit Workflow
For more information about setting up Materials and Mappings, see
• Setting up My Materials on page 104
• Setting up Mapping Presets on page 107
1. Material
a. Tooling Preset – prepares correct mapping of tools for each Layer in the design
b. Optimization Preset – performs correct optimization and sequencing for curves in the
design

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c. Production Preset – applies settings for production

2. Mapping Preset – use the correct Mapping Preset to prepare Layers and Layer Types for
applying optimal tools for each operation in the design. Most files maps correctly using the
default “Esko Default”.

Step 3 – Create Job

1 - Open File
When the job is added to iPC, it is available in My Jobs List.

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2 - Verify Job Settings

• Verify that the job has the Material and/or
the presets that you intended to use before
opening the file.
• Note: If the material in the file is not
registered in the Resource Database, you
get a “+” button after the material name.

Press the button to register the new

material to the Resource Database.
(For more information about setting up
Materials see Setting up My Materials on
page 104)

• Set the number of copies you intend to

produce using Ordered Copies > Set…

• Set the value in Ordered Copies.

• Use Rejected Copies to register copies that
cannot be used and needs to be produced
again.
• The fields Produced, Successful, Rejected
and Remaining and Rejected are used
for keeping track of Remaining Time in
producing the job. These are used by
Device Manager.

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• If job is correctly prepared with known technical lines and all selected presets are correctly
configured then. The file opens in state Job is ready for production

• Verify Layers and tools settings if needed. Change if this is a specific production or if a tool
needs to be replaced

• Change if this is a specific production or where you need to change something, for example
Tool Head Parking

Step 4 – Run Job

Place the material on the table.

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Press Start to produce the job.

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7. Manual Job Setup

This section gives you the general guidelines for how you can prepare a Job manually.

7.1. Layer settings

Layer settings.

1. Edit Layer (same as the cogwheel in Layer)

2. Add Layer
3. Add Regmark Layer
4. Copy Layer Including Curves
5. Copy Layer Without Curves
6. Remove Active Layer

Select Layer Type.

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Select Tool.
Mounted tools are shown in the list above the
line in the Tool Drop down list.

Update Layer Settings directly in the Layer

Edit Layer and Tool Settings via Edit Layer

(cogwheel) for more advanced options.

Note: For more information about all options for setting up the Layer, see the iPC User
Manual Chapter 5.8.

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7.2. Production settings

Production Settings

In Production, you set up how you want to

produce you job.

The things you can change are:

• Copies
• Quality
• Material Handling (Park After Table,
MultiZone, Sheet Feed, Roll Feed)
• Registration (none, Edge, Registration
Marks)
• Position (Main Reference or Panel
Reference point)
• Step and Repeat (copies in X and Y)
• Tool Head Parking (End position for Tool
Head after finished production)

7.2.1. Copies

Copies

Use Copies input box to specify the number of

copies you need to produce.

The tooltip gives information how to use

copies:

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7.2.2. Quality

Quality

Set quality slider according to your preference.

The slider has 3 positions, where the middle
position is the default.
You can set it on Accuracy for productions
where you have a need for more precise
results, and set it on Speed if you are more
concerened about the time it takes to
complete a job.

7.2.3. Material Handling

Material Handling

Use the correct Table Preset for your

production.

- Park After Table

Production is one copy at a time for the number of copies set in copies.
After each completed copy in the production, the Tool Head parks at the position set in Tool
Head Parking.
Vacuum is automatically switched on when producing and swithched off when job is paused,
stopped or finished.

- Park After Table Manual Vacuum

Production is one copy at a time for the number of copies set in copies.
After each completed copy in the production, the Tool Head parks at the position set in Tool
Head Parking.
Vacuum is manually swithced on and off by the operator.

- MultiZone Production
This Table Preset requires that the machine has multiple vacuum zones.
Production is one copy at a time for the number of copies set in copies.

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Copies are produced in different zones on the table and continue directly to the next zone if
the oprator has acknowledged that the next zone is ready for producing.
After completed production, or after completed copy when next zone is not acknowledger
ready, the Tool Head parks at the position set in Tool Head Parking.
Vacuum is automatically switched on when producing and swithched off when job is paused,
stopped or finished.

- Roll Feed
This Table Preset requires that the machine has conveyor belt. First copy on the roll must be
placed on the Table Top before starting.
Production is continuous, and when first (part of) job is cut, the Traverse will move to the back
of the Cutting Table, then transport the conveyor and the material forward. Feeding distance
is defined under Step and Repeat. Alternatively feed to front of table if Feed to Front of
Table is selected. Second copy is produced. First Regmark has to be identified manually if the
distance is not specified correctly, next copy will then be updated with the correct position.
After production is completed, the Tool Head parks at the position set in Tool Head Parking.
Vacuum is automatically switched on when producing, and switched off when job is feeding,
paused, stopped or finished

- Sheet Feed - Feed before

This Table Preset requires that the machine has conveyor belt and a Sheet/Board Feeder.
Production is continuous and a signal is sent to the Feeder to load a sheet. When ready, the
sheet is picked from the back of the table by the Traverse, and fed by the conveyor belt with
the length specified under Feed Length in the Production Tab. The sheet is registered with
the specified method defined under the registration section in the Production Tab. This
sequence will be repeated for each new copy and for the number of copies specified. After
completed production, the Tool Head parks at the position set in Tool Head Parking.
Vacuum is automatically switched on when producing and switched off when job is feeding,
stopped or finished. Use Pre-load function to feed more then one sheet on to first table.
Typically used if you want to have shorter feed lengths but still want to cut on first table
section.

- Sheet Feed - No Feed before

This Table Preset has the same Workflow as "Feed before", except that on first table, no signal
is sent to the Feeder. Use this preset if there is already a sheet placed on the table, typically
used if production was canceled.

- Manual Sheet Feed – Feed before / Manual Sheet Feed – No Feed before
This is a Table Preset for manual loading of sheets onto the conveyor by the operator. No
signal will be sent form iPC to any external feeding device.

- Feeder Stacker Production

This Table Preset requires that the machine has conveyor belt, Feeder and Stacker installed.
Production is continuous, the sheet is picked from the feeder and fed on to the table by the
conveyor. The feed length is determined by the specified sheet size. The sheet size is used to

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find the feed length that gives the most efficient way of using the Feeder Stacker system, and
Simultaneous or Sequential loading/unloading will be selected.
• Simultaneous loading and unloading is the most efficient way of producing. It can only
be achieved if the sheet is small enough to not extend into the stacker’s pick position on the
table while being cut.
When a job is cut, a new sheet will be fed on to the table, and the previously cut sheet will
be placed in the Stacker unloading area in a single feed. The Stacker receives a signal and
will unload the sheet simultaneously as the next copy is being produced on the table.

• Sequential loading and unloading is selected when the sheet size is too long to for
simultaneous production. The sheet will be fed and cut in the picking area of the Stacker.
When a sheet is cut, the sheet will first be unloaded from the Cutting Table, before next
copy is fed on to the table.
Registration of the job/Sheet will be done with the specified method defined under the
registration in Production Tab. After completed production, the Tool Head parks at the
position set in Tool Head Parking. Vacuum is automatically switched on when producing
and switched off while job is feeding, stopped or finished.
The sequence is repeated until specified number of copies are produced.
Vacuum is automatically switched on when producing and switched off when job is feeding,
stopped or finished.

- Feeder Stacker Production with Underside Camera

This Table Preset has the same Workflow as Feeder Stacker Production, except that the
Underside Camera is used.
The Underside Camera System scans the sheet from below, locates Registration Marks,
edges and the corners of the sheet, then calculates the job position relative to the corners
of the sheet. After feeding, the top camera will register the corner and apply the correct
placement.

7.2.4. Registration

Registration
iPC has 3 different options for registration:
• None
• Edge Recognition
• Registration Marks

None
Use this mode if the job does not have
registration marks and you put your material
parallel to the X and Y axis.
Job is started with reference to the selected
reference point + defined offsets

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There are no options to set for registration

type None.

Edge Recognition
This registration has a prerequisite that the machine has a camera connected.
Use this mode if the job does not have registration marks and the material on the table is not
parallel to the X or Y axis.

Sheet Position – Specifies the distance for the

Selected Reference Point where the camera
should search for the sheet corner.
Check Edge Distance – Specifies the
measuring distance to be used.
Check Direction – Specifies which method to
use for detecting the corner.
Register first table only – Use this setting
if you only need to detect corner for the first
copy.

Note: The Check Direction setting “Use corner

only” depends on the material on the table is
parallel to X and Y axis.

Registration Marks
This registration has a prerequisite that the machine has a camera connected.
Use this mode if the job has registration marks.

Compensation – Use the compensation

that fits your production. For most jobs Full
Compensation gives the best results.
Search Area – Defines the search area that
the camera uses when detecting registration
marks.
Ask Confirmation for First Mark – Use this
setting to specify if you want to confirm the
first registration mark for next copy in a job
with several copies.
Can be set to Never, First Copy and All Copies.
Adaptive registration – Use this selection if
you have several copies and want iPC to learn
what registration marks it needs for detecting
the position of the design.

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Use the slider to set the level to be used.
Accuracy means that all registration marks
are used for all copies and Speed means that
iPC learn how to minimize the number of
registration marks to use.

7.2.5. Position

Position

Use Position to set which reference point you

use for the job and in what offset from that
position you place the job.
You can use the function Move Job to
Reference Point if the file you use has an
internal offset.
The Update automatically selection can be
used for jobs with Registration Marks and
will keep the start position to the next job.

7.2.6. Step and Repeat

Step and Repeat

Use Step and Repeat if you want to produce

several copies in X and Y.
Press Update Copies to update “Copies”
to reflect the total number of copies to be
produced.
Enter Gap or Step Size between the copies.

7.2.7. Tool Head Parking

Tool Head Parking

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Set Tool Head Parking position to define

where the Tool Head should park.
The position can be set as an offset relative
to Main Reference Point, Lower right of job or
Upper right of job.

The position can also be updated by dragging

the Park Position icon on the screen.
The offset is updated according to the Relative
Offset you selected.

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8. Examples how to run a Job

8.1. Running a Job with Registration Marks

You will cut a job on a printed sheet using Registration Marks to achieve perfect print to cut
alignment.
The camera will find the different Registration Marks and use them to cut the job correctly.

1 - Open a Job and prepare to run it.

2 - Prepare the table:
• Place the sheet anywhere on the table with the correct orientation but slightly rotated.
• Make sure the Table Top Reference has been set.

• Set the Vacuum Sections.

3 - If necessary, click the Show all Layers button.

4 - Prepare the Production Setup

• Click the Production Setup tab.

• Check that Copies is set to 1.

• For Material Handling, select Park After Table.

• For Position, select Main Reference Point. Define a placement Offset by measuring the
distance from the Main Reference Point to the first mark.

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5 - Set the Registration:

• For Registration Type, notice Registration
Marks is automatically selected.
Note: This is because there is a
Registration layer.

• For Compensation, select Full

Compensation

6 - Click the Start button.

The Registration dialog pops up and the camera moves to the position defined by Placement
Offset from the Main Reference Point. The needed Registration Mark is rendered in red on
Production View.

Note: Should you want to stop it at this stage, you have to click Stop... on the Machine Panel.
Pause on the Operator panel does not work.

7 - Click the Registration dialog and use the keyboard arrows to position the camera over the
Registration Mark that is rendered in red in the iPC Production dialog.
Jog with the jog buttons on the Operator panel until the registration mark is completely inside
the camera view in the Registration dialog.
Note: This can also be done by pressing the keyboard arrows.
• A green circle will appear, indicating that iPC has recognized the registration mark:

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8 - Click

Note:To accept the registration mark, you can

also:

- Click the Start button

• Press Enter on the keyboard.

• The table measures the thickness of the
material.
• The camera is lowered to the right height
before proceeding to the remaining
registration marks in order to calculate the
exact position of all parts of the printed
job.

9 - Because the sheet was placed with a slight rotation, the camera view reappears.
Position the camera on top of the rendered registration mark and click OK.
The job is run with perfect registration.

8.2. Running a Job with Barcode

This is the automatic way opening and running jobs using Barcode.
The workflow for Start Production via Barcode… is the following:

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1. Put the printed material with Barcode on

the table
2. Open File > Start Production via
Barcode…

3. - The Start Automatic Production via

Barcode dialog pops up.
Fill in setting for Barcode Production
• Select location where Barcode production
files are stored. This can be a top folder,
iPC will look in sub folders also.
See below how iPC searches 1) My Job List;
2) Barcode folder and 3) History.

• Mapping
Select a mapping that will work correctly
for the Job. Most Jobs maps correctly using
“Esko Default”.

• Default Flute/Grain Direction

Should be set correctly if it is not available
in the source file.
The value is taken from Edit > Options
> General, but can be changed for each
production.

• Select action if barcode is not found

Skip job and load next job / Stop
production

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• Select table handling, Park after table,
Sheet feed, roll feed, MultiZone .... +
individual settings per preset
• Materials and Settings
From File; will use Material information in
file and apply default settings (prerequisite
is that the Material is configured in
Resource database.)
Custom Settings; will apply settings
selected in the custom settings dialog
Note: If the Job has material settings from
file, use Job settings "From File".

4 - Press Start.
The camera view window pops up.
Jog camera to the position of the Barcode and
make sure that the Barcode is detected
(When the detection is stable and you have a
file name identified in the Green section).
To start the production, press Start.

iPC will search three places in this order:

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1. My Job List
2. Barcode folder
3. History *)
*) To be able to seach in History, "Keep Job history” has to be enabled under Edit > Options
> General in iPC Menu, and "Show history" must be enabled in the "Show details" Window by
right-clicking the table header indicated in red.

Running automatic production

• The position of the barcode is remembered between each produced Table
• When a Table is produced, the conveyor feeds the next distance and positions the material
in the same position as the previous produced Table
• iPC detects the barcode, opens the job and applies the settings and produce the Table
• If the operator in the Start Production via Barcode dialog selected Ask Confirmation
to “Always”, the operator needs to confirm each detected job
The recommended setting for automatic production is the use the value First Job Only

• The production continues until there is nothing more to produce, or that the operator stops
or pause the production.

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9. Production workflows

9.1. Workflow 1 - Creating a design for iPC using

ArtiosCAD

This Workflow gives some guidelines:

How to prepare a Job file using ArtiosCAD and give guidelines how to add the file to iPC.

9.1.1. File formats and technical line definition

File formats generated from ArtiosCAD

Files created in ArtiosCAD can be saved and exported to a number of different file formats.

Native ArtiosCAD formats not pre-processed for the cutting table:

.ARD native ArtiosCAD file format for single design
.MFG native ArtiosCAD file format for multiple designs

Exported file formats that are pre-processed for the Cutting Table:
The default file format is ARD, used if you save the file or sending it to iPC using .JDF
(recommended)
.ACM file format for Kongsberg Cutting Table using X-Guide (can also be imported to iPC)
.PDF file format (not recommended)

9.1.2. Create a file using Run a Standard in ArtiosCAD

Follow this short tutorial to create a Standard in ArtiosCAD for a corrugated material.

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1 - From the menu, select File > Run a

Standard

2 - Select a design

3 - Select the material

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4 - Set dimensions

5- Save ARD file or output to iPC directly

9.1.3. How to use the ArtiosCAD output to iPC

1 - When the structural design is done go to Outputs > iPC > iPC -Submit Job-V3:

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2 - You are asked to save the Zip in the submit folder > press Save:

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3 - The ARD file will automatically be visible in the My Jobs in iPC:

9.1.4. How to configure an output from ArtiosCAD to iPC

This output will send the file directly to iPC My Jobs que, through the Submit folder.

To set it up do the following:

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1 - Setup Submit folder in iPC

A. Go to Edit > Options>
Connections here you can
review and set the link to
where the Submit Folder is
going to be located for your
system
B. Make sure this folder is
shared on the network so that
it can be reached by ArtiosCAD

2 - In ArtiosCAD go to Option
> Defaults > Outputs > Artos >
iPC.
The iPC output is a grouped
output and will create a Zip file
including a ARD file + JDF file
with metadata about the job.
You need to review settings for
three different data sets
• “iPC – ArtiosCAD file”

• “iPC JDF-V2”

• “iPC - Submit Job-V3”

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4 - Double click “iPC –
ArtiosCAD file” and check
the Layers that you like to be
included when outputting the
file to iPC

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5a - Double click “iPC JDF-

V2” > under Position > Device
Size fill in the table size of the
Device, this will split up the file
if the job size is bigger than
the working area

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5b - Under Processing >
Optimization option to No
optimization

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5c - Advanced > Fill in iPC

System Name (Computer
name where iPC is installed)

6a - Double click “iPC – Submit

Job-V3”

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6b - Under Grouped Outputs
tab > make sure ZIP is selected
for output type and both
outputs have “insert into Zip
archive” checked

Note: if you have changed

names of the outputs, you
need to replace them in the
output list

6c - Under Directories tab >

Make sure Directory is filled
in > Link to where the iPC
Submit Folder is located on
the network

Note: If you have more then one table, copy these three outputs and give them another
name. Repeat all settings to fit for your second table.

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9.2. Workflow 2 - Creating a design for iPC using Adobe

Illustrator

This workflow gives some guidelines about how to prepare a Job file using Adobe Illustrator
and give guidelines how to add the file to iPC.

9.2.1. File formats and technical line definition

File formats generated from Adobe Illustrator

• .AI – Native Adobe Illustrator format used for graphic workflow.

• .PDF – General format used for graphic workflow.

The recommended file format is PDF since default mapping for PDF files is available in iPC.

File preparations from Illustrator to iPC

For minimized manual intervention at the table, the designer need to prepare files with known
technical lines.
Supported ways of defining technical lines from Illustrator:
• Spot color (recommended)

• Illustrator Layer names

Prepare the Job with Layers and/or Colors that will be recognized by Mappings in iPC ensures
automatic tool mapping using Tooling Presets.
For more information about setting Layers, see Setting up Mapping Presets on page 107
Testlenke

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How to prepare a Job in Illustrator for iPC

What is ai-cut?
Ai-cut is a free plugin for Adobe Illustrator to prepare your jobs for Digital Finishing.
It lets you define Line Types, split Print from Cut data and add Registration Marks.
Ai-cut 16 and higher has been updated for integration with iPC.
Follow this short tutorial to create a PDF file in Adobe Illustrator.
This is a free tool that can be downloaded from Esko website: https://www.esko.com/en/
support/downloadsandlicenses/free-software.

Create the file

Step 1
Select one or multiple lines that you want to convert to cut path(s).

Step 2
From “Create Line Type” dialog, select the desired Line Type; this will recolor the selection.
Use “Move selection to Line Type Layers” to separate Cut from Print data into new Layer.

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This dialog can be found under Windows - Esko - Ai-Cut.

Step 3
Choose Remark shape and add Regmarks manually or automatically to your Job. The marks
will end up in a separate Layers. The Regmarks need to be output to both Print and Cut file.

Step 4

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Output files for Print and Cut. Split your design file into two separate files; one containing the
graphical data for Print and one containing Cut data for Finishing.

9.3. Workflow 3 - Creating a design for iPC using Third

Party RIP

This Workflow gives some guidelines on:

How to prepare a Job file using a third party RIP and give guidelines how to add the file to iPC.

9.3.1. File formats and technical line definition

File formats generated from Third Party application

Files created in Third party applications can have any by iPC supported file formats, most
commonly used are:
• .JDF - supports four barcodes with four different offset
• .CUT – i-script file with support for 2 barcodes with centered graphics (1 offset)
• .PDF – General format used for graphic Workflow, no barcode offset allowed

File preparations

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For minimized manual intervention at the table, the designer needs to prepare files with
known technical lines.
Supported ways of defining technical lines are by using Spot colors.

Prepare the Job with Colors defined as Spot colors that will be recognized by software and
later Mapped in iPC ensures automatic tool mapping using Tooling Presets.

You can also add Material to the file information. Selected material that will be used for
producing. Make sure the material is defined in the iPC Resources.

More information about material in Setting up My Materials on page 104

Create the file

Here you see a typical setup off a RIP Workflow.

It is not a detailed description, for information about how to set up your RIP Workflow for
print and cut filed, turn to the user manual from your RIP.
1. Load file into RIP
• Set up import to separate contours from design
2. Enter Printer setup
a. Set up size and margins for Job
b. Enable cutting contour and select option for cut Workflow, most common RIP's has a
dedicated Kongsberg output.
c. Select Print options for selection of Registration Marks and Barcode print
• Barcode is optional but can further improve optimal Workflow
3. Press Print to send the Job to the spooler and generate the cutting file

9.4. Workflow 4 - Creating a design for iPC using i-cut

Layout

This Workflow gives some guidelines on:

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How to prepare a Job file using i-cut Layout and give guidelines how to add the file to iPC.

9.4.1. File formats and technical line definition

File formats generated from i-cut Layout

Files created in i-cut Layout can have the following file formats (preferred for further
processing):

• .PDF
• .Cut
• .JDF (...... )

File preparations

For minimized manual intervention at the table, the designer needs to prepare files with
known technical lines.
Supported ways of defining technical lines are by using Spot colors.

Prepare the Job with Colors defined as Spot colors that will be recognized by software and
later Mapped in iPC ensures automatic tool mapping using Tooling Presets.

You can also add Material to the file information. Selected material that will be used for
producing. Make sure the material is defined in the iPC Resources.

More information about material in Setting up My Materials on page 104

How to prepare a Job in i-cut Layout for iPC

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1 - Open i-cut Layout

2 - Create a new Layout

3 - Give a document name, select a Substrate,

sheet size and set margins.

Note: Substrate is used as Material when

importing the file into iPC.

4 - Use Preparation > Add Graphic…

or use the Add Graphic button at the lower
right in the window.

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5 - Select one of more files to add to your
layout.

6 - Press the info button at the lower right in

the window.

7-
Set the values needed for each graphics,
most important is the cut path, select correct
technical ink. If no cut path is defined, you can
use the Create cut path tool.

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8 - Select Layouts tab and set values that fit

your production.
Gutter distance
Gutter distance depends on the material used.
For knife cutting, the recommendation is
minimum 5 mm. For milling, it needs to be
milling bit x 2 + 2 mm.

9 - When you are ready with you settings,

press Find Layouts Now!
Note: If you are using barcode and .CUT (i-
script) file format, its important to know that
only the first 11 charterers are used. so make
sure the first characters are unique.

10 - The layout is created.

Use Production > SmartMarks.. to create

Registration Marks and Barcode.

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11 - Select i-cut Marks

12 - Set the number of marks you need

13 - Recommendations:
• Recommended is to use Position Left &
Right to get one Barcode at top of Layout
and one at bottom.

• Recommended is to use Attach to Sheet

for optimal use of the sheet, and to make
sure Barcode can be located automatically
in production.

• Use Type QR to use the barcode that is

most efficient and easiest to detect when
sheet is rotated.

14 - When layout is ready with smartmarks,

Press Export Production Files in layout tab.
15 - Check ink mapping. All technical inks are
set to be sent to the cut file, with correct line
type name.
16 - Set file names and folders for print and
cut files.
17 - Select Folder for Report file.
18 - Use Settings for additional settings.

Under Cutting File Settings, you can pre-

sequence lines and add "Cut across gaps".
If you use this setting, be aware that
you should set optimization in iPC to No
Optimization or it will be sequenced.
A material Resource often uses a default
optimization.
For Cutting file, the recommendation is to
select Sequence lines and Cut across gaps.
When outputting JDF format, make sure the
ZIP JDF is selected. The JDF file needs to be
added to the iPC Submit folder.

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9.5. Workflow 5 - Underside Camera (USC) Regmark

preparations

9.5.1. Understanding the camera system

The underside camera system scans the sheet from below, locates Registration Marks, edges
and the corner of the sheet, then calculates the job position relative to the corners of the
sheet. After feeding, the Tool head Camera will register the corner and apply the correct
placement.

9.5.2. Registration Marks definition

Minimum Recommended Maximum

Regmark size 6 mm 8 mm 12 mm
0.24 in. 0.31 in. 0.47 in.

• Black or darker than the background with a high contrast

• To calculate the distance from the registration mark to the edge you need a light, print free
background from the registration mark to the edge
• Filled marks only

9.5.3. Placement of Registration Marks

Examples of registration accuracy

1. Best Practice - Scattered Regmarks

Greatest stability and highest accuracy (next page):

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For great stability and highly accurate result, the system requires the Regmarks to be
distributed and placed in a zig zag pattern along the sheet edges. Most important is Regmarks
close to the corners.
8 Regmarks along each sheet edge is a good practice.

2. Regmarks in a line along the sheet edge (next page):

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Most rips will only place Regmarks outside the bounding box of the print and often in a
straight line.
This may give less accuracy if you have warped sheets, but will in most cases be sufficient.
8 Regmarks along each sheet edge is a good practice.

• You will achieve best registration when Regmarks are placed close to the edge. Adding
Regmarks inside the print area will not lead to better accuracy

• Adding more Regmarks will not lead to a longer processing time.

• The only print compensation type that can be used is Placement

Registration Marks can be placed and distributed all over the sheet but the system will not
use all the marks. Only marks that are not obstructed by printed graphics (in one axis) towards
the edges, will be used by the system. Example:

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This Regmark is ignored by the system

It is important to place Regmarks outside the printed graphics and close to the sheet edges.
Optimal accuracy will be achieved when there are many Regmarks distributed close to the
back corners of the sheet in the feeding direction.

Minimum Recommended

Marks along each edge 3 8

Mark distance from print *) 5 mm 10 mm
0.2 in. 0.39 in.

Distance between Regmarks 40 mm > 40 mm

1.57 in. > 1.57 in.

*) outside bounding box of Regmark

9.5.4. Preparing Regmarks for USC using SmartMarks in i-cut Layout

and Automation Engine

A new SmartMark has been created for i-cut Layout and Automation Engine called: “Underside
Camera Marks”

1. Add one ups and create the nest

2. Add the SmartMark “Underside Camera Marks”

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Parameter Explanation
Size Regmark size
Minimum distance between Regmark and cut lines

Minimum Minimum distance that Regmarks can be placed from the edge
Distance
Maximum Maximum distance that Regmarks can be placed from the edge
Distance
Barcode It is optional to add barcode. Default is 4 QR code.

The algorithm places a frame along the edges based on <minimum distance> and <maximum
distance> from the sheet edge. This area is filled with Regmarks. Regmarks that are covered
by graphics will be taken away or move to an other position.

Installing SmartMark - this applies for icut-Layout versions earlier than 18:
Copy DTL script file “Flipsidecamera.dlt” to:
C:\esko\bg_data_marks_v010\dtl\gmf2k_v013 (either on your AE server or on your local machine)
If this folder is missing on your local machine, please use the folder:
C:\Esko\bg_data_signup_v010\marks_v010\dtl\gmf2k_v013
Once you have copied it and you restart i-cut Layout, you’ll have an additional SmartMark.

How to set the document size correctly

To place the Regmarks correctly, Prepress needs to know the feed direction of the material into
the cutting table.

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i-cut Layout (below) iPC Layer View (below) iPC Production View (below)
Table rotation 90 ° Table rotation 90 °

The red dot shows the In Layer View, the job appears In Production View, the Job
document Reference corner. with the printed side with will be mirrored automatically,
Printed side is facing up. regmarks facing up. when choosing a table preset
for USC.

E-learnings for Workflows are available on Esko's web site:

https://www.esko.com/en/support/blendedlearning

9.5.5. Preparing files manually in Adobe Illustrator

How to set the document size correctly

Prepress needs to know the feed direction of the material into the cutting table.

Adobe Illustrator iPC Layer View iPC Production View

Table rotation 90 ° Table rotation 90 °

The red dot shows the In Layer View, the job appears In Production View, the Job
document Reference corner. with the printed side with will be mirrored automatically
Printed side is facing up. regmarks facing up. when choosing a table preset
for USC.

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Regmarks can manually be placed into the design, but we recommend use of AI-Cut plug in for
Adobe® Illustrator®
See section
How to prepare a Job in Illustrator for iPC on page 45
i-cut Register Round Mark Tool

Example:

Keep in mind:

• Place Regmarks outside the printed graphics and close to the sheet edges
• Use the space in-between graphics when the print is close to the edge
• Avoid placing the Regmarks in a straight line

E-learnings for Workflows are available on Esko's web site:

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https://www.esko.com/en/support/blendedlearning

9.5.6. Preparing USC Regmarks in ArtiocCAD

Underside Camera macro is made for Layout / Manufacturing in ArtiosCAD

1. Create a "one ups" in ArtiosCAD

2. Nest the Layout in ArtiosCAD Manufacturing with a correct sheet size
3. Apply the USC macro
4. Export an EPS file
5. Open the EPS in Adobe Illustrator and add graphics
6. Save a PRINT file and optionally a CUT File
7. Use MFG file as the Cut file.

When using the MFG file as the CUT file, a USC mapping is then recommended. The Print
side of the job needs to face up in the Layer view in iPC. The table Preset for USC will mirror
the job in Production view when it is applied.
Underside macro and how to install and use this macro is explained in one of our e-Learnings
that are available on Esko website:
https://www.esko.com/en/support/blendedlearning

See also Esko Learning and Development:

https://lnd.esko.com/course/view.php?id=1838

How to set the document size correctly

Prepress needs to know the feed direction of the material into the cutting table.
Red dots below show document reference corners.

ArtiosCAD Manufacturing (below) Adobe Illustrator (below)

In Manufacturing, the outside (printed side) is In Adobe Illustrator, the outside (printed side)
facing up. is facing up.

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iPC Layer View (below) iPC Production View (below)

Table rotation 90° Table rotation 90°

In Layer view, the job appears with the printed In Production view, the job will be mirrored
side with regmarks facing up. MFG files need automatically when choosing a table preset
USC mapping. Corrugated material is by Esko for USC.
Default mapping the material so it is open
with inside facing up. For USC it is needed that
the printed side is facing up.

9.5.7. Operation with Underside Camera

The operation is like Feeder Stacker Production, except that the Job is run face down. The
camera will read the Regmarks from the printed side that is facing down on the table. The Job
will be creased and cut from the opposite side.

The material size must be added into Advanced > Resources > My Materials.
Material size must be set correctly, for the Feeder to feed the correct distance, and for the
camera to scan the sheet correctly.

In Layer View, the printed side with Regmarks is facing up. In this case the material will be fed
on the table with this side facing down.

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Note: Do not mirror or rotate the Job in Layer View. This is automatically done when selecting
correct Table Preset for Underside Camera.

Note: If the Job orientation does not correspond to the way it shall be produced, you have the
option to rotate it in Menu Job > Rotate 90° CW/CCW. However, the best approach for making
corrections is to return to Prepress, rather than modifying files in iPC.

For this operation, you have two choices of Table Presets:

• Feeder Production with Underside Camera

• Feeder Stacker Production with Underside Camera

There are only two ways to flip the Job when placing it face-down in the In-stack of the
Feeder. Select either Turn or Tumble, so the cutting curves match how the Job will be loaded
on the table.

Turn means that the material is flipped around the length of the table.
Tumble means that the material is flipped around the width of the table.

Note: It is important to have the Cut file corresponding with the printed side with Regmarks
facing down on the table, since Underside Camera reads Regmarks from below.

9.6. Workflow 6 - Design from Digital Flexo Suite to iPC

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This chapter describes how to prepare and setup an optimal Workflow with a high level of
automation for customers using Digital Flexo Suite (DFS).
iPC v2.2 has a complete new set of Mapping and Tooling Presets for flexo to make it easy to
set up a customizable workflow with cut files from Digital Flexo Suite.
The tooling presets also introduce a new dynamic height setting, where the cutting depth is
calculated based on material thickness. This reduces the amount of needed tooling presets
significantly.
The Tooling presets cover all possible workflows in DFS including straight and beveled cutting
from front, cutting from back with scribing, full Pre Mount Workflow and all available outputs
from PlatePatcher.

1. DFS operator creates a layout in the Merger and submits the Job simultaneously to a CDI
and a Cutting Table running iPC
2. The Job is automatically imported via the submit folder.
3. When the flexo plate is processed and ready, the operator opens the Job in iPC and cuts the
plate.

9.6.1. Setting up connection between DFS and iPC

To setup an optimal Workflow, it is necessary to adjust different settings in Digital Flexo Suite
based on customer needs and wishes. DFS utilizes i-script files instead of the old ACM format.
The new i-script format includes more meta information like material and thickness. The files
are sent to the iPC submit folder, where iPC then imports the files automatically and show
them in the Job list.

Choose an optimal location for the iPC submit folder

To make a stable uninterruptable Workflow, choose a location for the submit folder on an
“always on” data server, preferably a folder next to the LEN files source library. This location is
already accessible on the DFS workstation.

Note: Make sure the location for the submit folder is always accessable, or the files from DFS
can be lost.

Note: Always create the actual target folder from the Kongsberg Windows user. When
importing the files, iPC deletes them from the folder and sometimes security issues can
prevent iPC from doing that, even though all permissions are setup correctly.

Set up file output destination in DFS

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Open Merger and go to Menu > XL-Cut

Workflow Editor
For all Workflows, choose correct folder
location in “Kongsberg Target Path”
Remember for each Workflow to save before
proceeding.

Note: All Workflows share the same submit

folder location.

Set up file submit folder location in iPC

Open iPC and go to Edit > Options >

Connections
Choose same folder as “Submit folder”
The network location used for the files should
be mounted as a local drive.

Set up optimal basic Workflow

Note: This section is important to discuss with the customer's Workflow responsible.

In the XL-Cut Workflow editor, always choose iPC as output device. Be sure to do this for all
Workflows and save.

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For PlatePatcher, similar Workflow settings apply, except that User Defined Material Name is
not available. All files will automatically be named Flexo Carrier Sheet.
In the XL-Cut Workflow Editor, you can basically choose between two different ways of
naming the “material” of the DFS Jobs when submitted to iPC.

Option 1 – User defined name as material name (preferred)

The best option is when a user defined name is used for each XL-Cut Workflow. It is also good
if the customer has many different plate types. In iPC, this name appears as “material” and
the list of materials can then be limited to the number of XL-Cut Workflows. Different XL-Cut
Workflows can of course share the same material setup in iPC.

Note: This naming of “material” works the same way as the old MAT info from X-guide.

The advantages are:

• “My Materials” list in iPC will be reduced to the number of DFS Workflows
• Different “My Materials” setups can be used on the same plate type
• If the customer creates new plate types, changes are not needed on iPC

Option 2 – Use plate type as material name (optionally)

If customer has a very limited amount of flexo plates, you can use the “auto” setup for material.

This will use the plate name as material name on iPC, e.g. DPR 1.70 (067).

The advantage is that each plate has its own material setup in iPC, and therefore can be
customized if needed. The disadvantage is that when new plates are created on the CDI, a new

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plate also needs to be set up on iPC, and it is also not possible to have different iPC setups for
the same plate in iPC, for example straight and beveled cutting on a 2.84 plate.
If the optional plate name as material is used, discuss with the customer to clean up the plate
list on the CDI, both the amount and naming.
If the customer has multiple CDIs, use the same names for the same plates on all CDIs where
possible. This will reduce the number of plates to set up in iPC.
Try to follow the default naming in Grapholas like DPR 1.70 (067).

9.6.2. Import Mapping and Tooling Presets for Flexo

It is important that the new set of Import Mappings and Tooling Presets for flexo are used
together. They will not work with the older Presets in the library.
The new set of Mapping Presets for flexo consist of a single i-script mapping and three
different Mappings for ACM files. This is necessary since several P-channels are used for
different types of layers when cutting respective flexo plates from the back, front or cutting
flexo carrier sheets.
The bundled Mapping Preset “Esko Default Flexo” utilizes the single i-script mapping
“Flexo_Mapping_v2” and also the ACM mapping named “Flexo ACM Carrier Sheet”.
This default bundle will work for all customers with newer DFS including corrugated customers
that sometimes need to redo old ACM files from their “pre-iPC” archive.

Note: If “Flexo_Mapping_v2” is present, rename it to “Esko Default Flexo” and follow the
instructions in the illustration above.

Using i-script files – DFS output device set to iPC

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Default Workflow uses i-script Mapping and the *.dfscut files from DFS must be send to iPC
using the submit folder. It is not possible to open the files using the [Add…] button.
However, if redoing old ACM files – most likely it will only be flexo carrier sheets - you can still
use the submit folder, but the files will not automatically be associated to any material. See
next section how to best open these files manually.

Using ACM-files – DFS output device set to X-guide

If you use DFS older than v14.1, you must use ACM Workflow. You can still send files to the
submit folder, but iPC can only use one mapping bundle automatically. This means iPC can’t
distinguish between ACM-files needing different mappings (front, back or carrier sheet).
If you need to use the back or front mapping for ACM, you must therefore create new mapping
bundles containing these two mappings. You can still use the submit folder for a default setup,
e.g. carrier sheets, and then open front or back manually:

1. Select Add... button

2. Select the wanted file
3. Select Material
4. Select Mapping
You must therefore always
select material manually after
import.

ACM Workflow for iPC is only supposed to be used if DFS is older than v14.1, or when redoing
archived carrier sheets at customers done before upgrade to iPC.

Understanding the Mapping structure for flexo

To customize the new Presets, it is important to understand the Mapping structure. DFS
outputs 33 different layers from all possible Workflows and iPC cannot handle all these
layers with individual settings.
To keep most flexibility for customization, all Layers from DFS are imported and their Layer
names are preserved separately. Therefore, many of the Layers have to share the same Layer
type in the Tooling Presets. Each Layer type can only have one common setting, so multiple
Layers sharing same Layer type also share all Layer options like if the Layer is enabled for
production, tool usage, GUI color, speed, etc.
Below table illustrates the complete Mapping:
• The left part of the table shows the output from DFS – i-script and the 3 ACM mappings
• The right side of the table shows the iPC Layer Name and not at least Layer Type
• The upper part of the table shows all channels for Flexo Plates

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• The lower part of the table shows all channels for Carrier Sheets
For flexo Plates, the working sequence for the layers on iPC are always as this:

1. Scribing – Kiss Cut tool

2. Plotting – Ink Tool
3. Drill – Drill Tool
4. Cutting without “safecut” – Staggered job, Line Edit, UnderCut
5. Cutting with “safecut”

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Note: The only Layer from DFS not imported is Reference / P32

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9.6.3. Create flexo materials on iPC

The preferred and most easy way to create multiple materials in iPC is to make a simple test
job in Merger and send it multiple times using all possible XL-Cut Workflows or plates based
on whether option 1 or option 2 was selected in section Set up optional basic Workflow.

In iPC, open all Jobs and use the orange

+sign to add the material to the My Materials
list. Using this method, you avoid spelling
errors but creates a lot of “dummy” jobs also
appearing on the CDI’s

In the New Material pop-up box, the material

name of the test Job is prefilled:
For each material do the following:
1. Select Flexo Plate as Material Family. For
Carrier Sheets select Flexo Carrier Sheet
2. Enter a default thickness. See note below
3. Select Flexo as appearance
4. Save by pressing [OK]

Note: Upon Job run, the thickness is always used from the Job. iPC uses the thickness to
calculate cutting depth and camera height for correct focus when searching for Registration
Marks. For beveled cutting Workflows, select a value between 3.5 and 4.0 mm / 0.14 and
0.14 in. This will make both Tooling Presets for beveled cutting appear when later selecting
preferred Tooling Preset.

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For all materials created, open

the Resources window under
the Advanced tab to edit
more properties necessary for
flexo plates.

1. Select My Materials to the left

2. Select your flexo material
3. Select “Do not measure, use specified setting” in Material Measurement. This prevents
iPC to use the measuring foot upon job start to measure for material thickness and
presence.
4. Enable the “Extra tool lift for uneven material”. This forces the knife to use extra tool lift
prevent sticky flexo material to be lifted by the knife.

9.6.4. Apply presets to the flexo materials

For each material you need to apply 3 presets:

For all flexo and carrier sheet

material, select the following:
“Use material specific settings”
See the following sections
for selection of presets

Apply a Tooling Preset to each flexo material

Select needed Tooling Preset according to DFS Workflow or material.

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Flexo Plate - BackCut - (Straight knife) / BLD-DR8160
• Scribing/plotting for Image Label, Microcross and Short Centerlines
• Disabled for production: Centerline Long and Image Middle Lines

Flexo Plate - FrontCut - (Beveled knife) 1 - 4 mm / BLD-SF212 & BLD-DR8160

• Scribing not available
• Disabled for production: Image Line Editor

Flexo Plate - FrontCut - (Beveled knife) 3.5 - 7 mm - Reduced Speed / BLD-SF212 & BLD-DR8160:
• Scribing not available
• Disabled for production: Image Line Editor

Flexo Plate - FrontCut - (Straight knife) / BLD-DR8160

• Scribing not available
• Disabled for production: Image Line Editor

Flexo Plate - PreMount Raw Plate - (Straight knife) / BLD-DR8160

• Only Image Label plotting
• Straight cutting at low speed

Flexo Protective Foam - Rigid Material Knife / BLD-SR8184

• Made for cutting “packaging” foam using the regular front or back cutting files.
• Will only cut Image Cut and UnderCut
• Disabled for production: Staggered Cut and Line Editor Lines

Flexo Carrier Sheet

• A single preset used for all carrier sheets.
• Disabled for production: Image Position

The drop-down list will filter the Tooling Preset showing only the one for the current plate
thickness.
WARNING - For all Tooling Presets – AVOID EDIT IN THE JOB WINDOW
There is a known risk that the Tooling Presets can be corrupted if edited and updated in the
job window. Instead go to the Recourses window to edit values if needed.
Try not to change the default cutting depth (107% from material top) used for most cutting
layers. Instead adjust the height of the knife tool in the tool adjust.

GUI Interface colors in iPC for flexo jobs

To increase the operator usability, specific layer colors are used to identify the different cutting
elements the Job consist of. Layers not using “safecut” requires the corners to be taped to the
table mat.
All cutting elements using “safecut” (always cutting towards the corners) are black. The rest has
blue or dark cyan. This guides the operator when to tape the corners.

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Colors used for flexo plates:

Register marks/camera Magenta

Text plotting Red

Drill Brown

Staggered Cut, Line Edit Blue

UnderCut Dark cyan

Image Cut and Line Edit rectangles Black

Colors used for flexo plates:

Register marks/camera Magenta

Text plotting Red

Drill Brown

Staggered Cut, Line Edit Blue

UnderCut Dark cyan

Image Cut and Line Edit rectangles Black

For Flexo Carrier Sheets, the following colors are used:

Dye Cut Dark Green

Text, marks, labels and centerline Red

Patch Position Blue

Drill Brown

Bevel Cut (PreMount post cut) Dark cyan

Cut (Carrier sheet contour) Black

General remarks to settings for flexo Presets

For all Presets, the following Layers are “disabled for production”, since they are rarely used:
• CenterLine Long (plot)
• Image Middle Lines (plot)
• Image Line Editor

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General remarks to settings for flexo carrier sheet preset

For all plot lines, the speed is 100% for text, regmarks and other Layers containing small
elements, and for the rest, speed is reduced to 50%.

Apply an Optimization Preset to each flexo material

For optimization preset always select “Flexo Plate”

All optimization comes from DFS and no further optimization is needed.

Apply a Production Preset to each flexo material

For flexo plates always select “Flexo Plate Manual”

For Flexo Carrier Sheets always select “Flexo Carrier Sheet Manual”

9.6.5. Tips & Tricks

• There is a new ACM Viewer v14.1, that can read i-script files (*.dfscut). It is free to install and
does not require any license.

9.7. Workflow 7 - Design from Esko Device Manager to

iPC

This workflow gives some guidelines how to prepare an optimal workflow for customers using
Esko Device Manager for creating a design and then que the job for automatic addition to My
Jobs in iPC.

Submitting Single CAD Files

In this Workflow, Automation Engine sends
ARD of MFG files directly to the iPC. Each input
file arrives as one Job in the iPC My Jobs.
This Workflow is often used when producing
packaging, POP material or box samples.

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Submitting Nested Layouts

This Workflow merges files together before
submitting them as one layout to the iPC. The
merging is done by the Gang Run Printing
merger. This merger can also make layouts
where items are nested to optimize material
usage. This Workflow is often used when
producing signage.

Cutting CDI plates

In this Workflow you use a Cutting Table to
cut a flexo plate that you made on a CDI. This
is often used when the flexo plate contains
separations with a staggered cut or contains
small parts of a DFS PlatePatcher Workflow.

Note: For more detailed information, see section "Kongsberg Production Workflow" in
document "Automation Engine 18 - Complete Manual"

9.7.1. File formats generated from Esko Device Manager

Files created in Esko Device Manager for processing in iPC is a combination of files. One
structural file (ARD/MFG/CGF) and one file (JDF) including information about material and
cutting.
The two files is combined in a .zip file, further processed by Kongsberg Queue Service (Queue)
for creating a Job in iPC My Jobs.

9.7.2. File preparations for Device Manager

For minimized manual intervention at the table, the designer needs to prepare files with
known technical lines.

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Supported ways of defining technical lines are by using Spot colors.

Prepare the Job with Colors defined as Spot colors that will be recognized by software and
later Mapped in iPC ensures automatic tool mapping using Tooling Presets.

9.7.3. Export file from Esko Device Manager for further processing

Device Manager has the functionality to send file for printing and for queueing the file to a
Kongsberg Cutting Table.

Note: For more detailed information, see section "Kongsberg Production Workflow, Workflow
examples" in document "Automation Engine 18 - Complete Manual"

9.7.4. Importing files to My Jobs

Files that are sent from Device Manager, will automatically be added to My Jobs in iPC. Make
sure the material is defined by Device Manager and available in the iPC Resources, so that cut
settings can be applied and file estimated.
More information about material in Setting up My Materials on page 104

9.8. Workflow 8 - Structural design with graphics to

print and cut

This Workflow gives some guidelines: How to create a structural design in ArtiosCAD > add
graphics in Adobe® Illustrator® and export an normalized PDF (Esko PDF) > nest the job on a
material sheet size in i-cut Layout and send a print file to the RIP and a cut file to iPC for cutting

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on the Kongsberg cutting table. You need to install the free Adobe® Illustrator® plug-in called
Esko Data Exchange.

Note: Data Exchange plug-in is a free and simple to use plug-in for Adobe® Illustrator® that
acts as a bridge between Adobe® Illustrator® and Esko applications. The XMP metadata of an
Esko normalized PDF will contain the ArtiosCAD line types, material information and the flute
direction.

Free downloads from esko.com:

https://www.esko.com/en/support/downloadsandlicenses/free-software

9.8.1. Create a structural design “one up” in ArtiosCAD

Run a standard: File > Run a Standard

Add 5 mm bleed, and do not forget to press

OK.
Save the ARD file.

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9.8.2. Add graphics in Adobe Illustrator

Open the ARD file.

Structural design layers are locked. Layer 1 is
for Graphics.

Expand the bleed layer:

Window > Esko > Structural Design > Expand
Structural Design Layer...
A new layer will be created with copied
geometry. A good practice is to give the layer a
logical name.

You can now select the bleed line and give it a

fill color and finalize your design.

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Export this file as Esko PDF (Normalized PDF)

We recommend version 20 of Data Exchange
plug-in for Adobe® Illustrator with improved
support for ArtiosCAD line types.
In this version make sure the Ink Manager
is set to Normalized PDF. Windows > Esko >
Ink Manager. When this is done, go to File >
Export > Export AS > Esko PDF
In older versions go to: File > Export > Export
as > Normalized PDF
• The Normalized PDF contains a link to the
ARD file. It is important to not move the
ARD file. Best practice is to save both files
together.
• It is also recommend to save an original
Ai file, in case you need to go back and
change something.

9.8.3. Nest job in icut-Layout

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Create a nest
1. Select a sheet size with a material
2. Add the Normalized PDF that was created
in Adobe Illustrator that contains both
structural design and graphics. In the
Graphics view you can see the linked ARD
file.
3. Nest the job on the material size with
setting you like and make sure you have a
layout name.

Add SmartMarks
1. Regmarks
2. Add barcodes
3. Set the Ink to black for the regmarks and
barcode

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Export production files…

1. Select folders for production files.
2. Select output format for your cutting file.
You can choose between MFG or a JDF file.
If working with barcode, you have to select
JDF output.
Note: From i-cut Layout version 20, we
recommend a JDF (zipped) because it contains
more information and will contain a MFG
instead of a CGF file if a CAD file is used.

The line type names will be taken from the

CAD file and will overwrite the settings in ink
mapping for these files.

A Print and the zipped file are now saved to

your folder.

What a JDF (Zipped) file contains:

1. A JDF file (Meta data)
2. A folder with a MFG file and a PNG thumb
nail file

Produced the job:

1. Send Print file to the Rip to be printed.
2. Open the Zipped JDF file or MFG file in iPC
and prepare the file for production.

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10. Understanding print compensation

for soft signage

Achieving an acceptable result for Print-to-cut registration when producing fabric graphics
can be challenging due to the extreme non-uniform distortion incurred in the printing
process, especially if the graphics are sublimated. Special care must be taken throughout the
design and production processes (printing) to achieve acceptable results. Even when print
is compensated, it is extremely hard to get correct rotation and placement on jobs that are
longer then table.

Depending on the material characteristics and what print process was used, it might be hard
to get a 100% correct result due to non-uniform distortion. The better distortion, stretch and/
or shrink is compensated upfront in the printing process, the more accurate result can be
achieved in the cutting process.

Running Jobs with Print distortion

Running jobs with distortion (Stretch, shrink, often non-uniform) requires some extra
knowledge about iPC and the compensation algorithms. This especially applies to Jobs Longer
than Table (JLT).

Jobs can be split into two different categories:

• Jobs where cut line need to match the printed outline (follow distortion)
• Jobs where cut line needs to be cut to exact size, as designed (follow original cut file)

With i-Cut Production Console (iPC) there is a choise how to compensate for these print
distortions. iPC has six compensation methods and it is important to understand what each
of them are doing, in order to select the correct one. See description of these in section
Compensation Types in the iPC User Manual.

What to do when the job needs to match the printed outline (follow
distortion)

If the size of the final job is not critical for the application, the most important is to not cut
away any of the graphics (stretch) or have white space on the borders (shrink). For these jobs it
is best to use Full compensation.

Be aware that this compensation algorithm follows all distortions found. This compensation
type will change the original curve and adapt to what was actually printed, so if there is non-
unified stretch or the print is warped, that will also be reflected in the cut.

If there are wrinkles during feed, this will be interpreted as print distortion and also influence
the cut.

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What to use when the job needs to be cut to exact size

Flexible materials are often stretched, but the applications often require the original size to be
kept, typically when the result shall fit within aluminum frames.

In these cases Register Curve or Move Job are the only compensation types that will work.
Size is always kept, but rotation and placement are calculated based on Register Marks found
and in best relationship to the scaling.

Examples of what can go wrong

The below images illustrate what might occur, where placement and rotation might look
wrong. This is due to non-unified distortion.

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Sometimes joint problems come from material shrinking/stretching in X/Y during feeding.
If this happens, the next frame will still be cut in “Exact size”, as defined by software on
the section before; leaving it to look like the joints are not matching up because it is not
compensated for shrink and/or stretch. It can often be seen that this is what happens if the
shift distance at joints is different on the left and right side.

Material that is shrinking/stretching during feed is therefore better produced using Full
compensation, which will adjust size on each frame. Changing the Conveyor Speed and using
Motorized Roll Feeder can improve the shrink/stretch condition. Tension controlled conveyor
belt is recommended.

Having X and Y shift activated when this happens might make the situation worse.

Option for placement of curves

When using compensation type for exact size, Curve Anchor can be defined, see -F- Curve
Anchor in section 5.8.5. Registration in iPC User Manual. This dedicated iPC features is needed
when cutting panels or prints that need to be mounted next to each other, or to ensure that
important text or graphics are not cut off.

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Note: Pay attention to how artwork is prepared. The image to the right is cut to the exact size,
but it looks wrong because the black frame in the graphics is cut off. This kind of graphics
should be avoided when working with materials that tend to shrink/stretch during the
printinging process.

What to do for Jobs Longer than Table, when the job needs to be cut to
exact size

The calculation of rotation and placement will be determined upfront based on the scaling
found on the first section (table) only.

A perfect cut result of jobs that must be cut to exact size will therefore demand perfect feed
• No wrinkles
• No material movements (straight feed)
• No material distortion (stretch/shrink) created by or during feeding.

When using textiles and other unstable materials, it is hard to keep all these things under
control.
• Materials might be winded to hard during printing and retracts during fed.
• If using Passive roll feeder, to high tension or to high conveyor speed might stretch the
material.
• If a roll is winded uneven, folds are created when pulling the material onto the table.

For best result we always recommend motorized roll feeder and tension controlled conveyor
system.

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A number of software options are available in iPC to help you achieve
best print-to-cut quality on Jobs Longer than Table:
• Compensate for conveyor feed shift, see Compensate for shift during feed in iPC User Manual

• Ignore material rotation of the Job. See section -G- Ignore Material Rotation in iPC User
Manual.
For Jobs Longer than Table, it is always recommended to use the function Ignore Material
Rotation on curves longer than three table feeds and when dealing with Jobs Longer than
Table and non-uniform printed jobs.

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11. Appendix 1 - iPC Resources

A well prepared system gives you the opportunity to set up optimal workflows for your
production.
This section will explain all the parts of iPC that you can configure to make your production
Workflow more efficient.

11.1. Material is Key

i-cut Production Console (iPC) is the software that controls your Cutting Table.
In iPC, we base the Job Settings on the material that is used for producing the job.
By focusing on the material, we can optimize tools and settings that will give a good result.

This document describes several workflows based on the concept of filtering on material.
We call this concept Material is Key.

Material is Key:
1. The Material is defined in the upstream application that creates the design or layout (input
file)
2. The Material is defined in iPC and mapped to Tools and Production Settings
3. The design has a structure that can be interpreted by iPC (examples are Layers, Line Types,
Spot Colors)

Given that these three requirements are met, the job is ready for production.

11.2. Resource Manager

To achieve an optimal workflow, Material and Resources needs optimal setting.

This is administrated using the Resource Manager.

The Resource Manager handles all settings in the Resource Database and has two major
functions:
1. Storage of resources
2. Mapping between resources to make it easier to set up an optimal production
The Resource Manager stores materials and holds the mapping to presets with settings
required to set up the job for an optimal production.

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Tool(s) to use is detected via the Mapping Preset and the Tooling Preset.
• The Mapping Preset defines how the geometry in the design (input file) is mapped to iPC
Layer Types.
• The Tooling Preset defines how to assign correct tools to layers using Layer Types.

Production optimization is detected via the Optimization Preset and the Production Preset
• The optimization Preset defines how curves will be optimized for optimal production.
• The Production Preset includes the Production parameters used in the Production Tab.
The key resources for optimal workflow are set up in the Resource Database.

11.3. Setting up Resources

Use the Resource Manager to set up the Resources you need for your optimal production.
The Resource Manager includes factory default settings for the following:
• Mapping Presets
• Material Families
• Cutting Profiles
• Tooling Presets
• Optimization Presets
• Production Presets

Mapping
You can change the Mapping Preset for the job by selecting one of the presets
available in iPC.

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The mapping can be a default mapping prepared by Esko, or a preset fine-tuned for
specific designs not handled by the default presets.

Material Families
Select correct material for the production.
In a well prepared installation, the material in turn uses a Default Cutting Profile
that fully defines how to produce the job.

Cutting Profile
The Cutting Profile is an umbrella setting that combines the settings of Tooling
Preset, Optimization Preset and Production Preset.
Cutting profile is a concept where you save a set off predefined settings that can be
used for more then one material.
More commonly is to use Material specific settings.

Tooling Preset
The Tooling Preset is the setting for mapping layers in the file versus the actual
tool that should be used for producing.
Tooling Preset should be set up to cover the different designs sent to iPC, and for
each Layer Setup map the correct tools for production.

Optimization Preset
The Optimization Preset is used to make the best possible curve optimization for
each job.
Optimization can be defined for standard production or sample making designs.
The system is delivered with a set of Optimization Presets, but it also possible
to define and save specific Optimization Preset for jobs that needs specific
optimization.

Production Preset
The Production Preset is used to tell iPC how the job will be produced.
It contains information such as
• # of copies
• Quality
• Table Preset
• Registration
• Reference Point
• Step & Repeat
• Tool Head Parking.

Prepare Materials and Tooling Presets in the Resource Database:

1. Add material(s) and select a Material Family for each Material you expect to use.

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The steps are explained in Setting up My Materials on page 104.

Note: If you do not find a Material Family that fits your need, you add your personal
Material Family
2. Go to Tooling Presets and find one Tooling Preset for each material you added.

Note: If you do not have the Tooling Presets you need, you can create your own.

The steps are explained in Setting up Tooling Presets on page 93.

3. For each Tooling Preset - Highlight the Tooling Preset and press Add to make your
material applicable to your Tooling Preset.
4. Go back to each material and select the Cutting Tab, complete with Tooling Preset.
5. For materials where you want to add specific optimization and production details, add
Optimization Preset and Production Preset to the Cutting Tab.

If you need specific settings for any of the Presets, not provided in the factory defaults, follow
the Preparation guideline in Preparing Resources for optimal production on page 93.

11.3.1. Chain of events when creating a new Job

This picture illustrates how resources are applied when you create a new job.

Create Design
1. The designer creates a file with technical lines that can be interpreted by iPC.
2. The file includes information about the material that is to be used when producing.

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Add File
1. The import process for Mapping Preset maps the technical lines to separate Layers with a
dedicated Layer Type.
2. The import process for Resource Manager takes the Material as input and looks up the
dedicated resources Tooling Preset, Optimization Preset and Production Preset for this
specific material.

Open
1. The Tooling Preset apply correct tool to the layers identified by the Mapping Preset.
2. Curves are optimized according to settings in the Optimization Preset.
3. Production settings from job is set according to the Production Preset.

Run Job

Put the material on the table and produce the job.

11.4. Job Estimation

When the job is opened and prepared for production, the Job Estimation starts.

In the Job List in My Jobs, there is one row for each job added to iPC.
• The column Estimation gives the readiness state.
• The column Remaining Time shows the remaining time for each job in the list.

The Estimation can have four different states.

File just added or new Job Settings is applied.

Estimation is in progress.

Job Estimation performed, but job is not ready and need Tool or Layer edits.

Job Estimation performed, but job is not ready. Probable cause is “tool not
mounted”.

Job Estimation completed. Job is ready for production.

Note: The job can be opened at any time when it is added to the list.
The Estimation indicator just gives information of the time it takes to produce the job if it is
fully prepared.

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11.5. Preparing Resources for optimal production

Use Resources to configure your settings for an optimal workflow in your iPC environment.
You maintain your settings in Resources via Advanced > Resources…

When you open up Resources the main window is displayed.

Use menu entry or press button to open up settings for each category.
We now give information how set up Resources, one menu item at a time.

11.6. Setting up Tooling Presets

The description of Tooling Presets is displayed when you hoover the cursor over the Tooling
Presets icon.

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iPC is delivered with a number of factory default Tooling Presets.

If you have jobs with materials and tools that match the factory default Tooling Presets, you
are ready to use them.

Hoover this info button to get a short

description of Tooling Presets.

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The Edit Layer button gives you the ability to
change specific Layer setting for the Tooling
Preset.

If you do not find a perfect match for your production, you are able to define your own Tooling
Presets.
Factory default Tooling Presets are defined with a starting point out from Material Families
and the thickness range.
They are not made for specific materials (brands).

Whenever you add a specific material to Resource Manager, the Tooling Preset for
corresponding Material Family and Thickness range will be applicable for the new material.
This Tooling Preset (Factory Default) may not give you optimal settings for your material. We
recommend that you to make your own Tooling Presets for the specific material that give you
optimal settings.

There are different ways to set up your own Tooling Presets:

1. Convert Cutting Keys to Tooling Presets
2. Create new Tooling Presets from a configured job
3. Use a pre-defined Tooling Preset – Change settings to match job – Save as new Tooling
Preset
4. Use i-cut 7 Cutting Keys and prepare as Tooling Presets

11.6.1. Use a pre-defined Tooling Preset

Use a pre-defined Tooling Preset – Change settings to match job – Save as new Tooling
Preset
Create a new Tooling Preset from a job and an existing Tooling Preset.

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Open a representative job with Layers.

Apply a Tooling Preset that you find match

material, Layers and tools for your job.
Open the select Tooling Preset wizard from
Layers “Tooling Presets->Select Tooling
Preset…”

“Select Tooling Preset” wizard starts.

Step 1 - Wizard starts.

Select Material Family and press “Next”.

Step 2 - Select a Tooling Preset that best

matches your job.

Select Tooling Preset and press “Next”.

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Step 3 - Assign you Layers in the job to Tools.
You assign the layer(s) by dragging them over
correct tool in Tools and Layers.

Note: If you hold down the Ctrl key, you can

connect the layer to multiple tools.

When you assigned layer(s) to tool(s) and feel

ready, press “Finish”.

The Tooling Preset is now assigned.

The job is not ready for production.

Use Edit Layer to change settings.

For this milling job, the Tool Offset is changed

from Outside to Centerline.

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The job is now ready for production. To

update the Tooling Presets, select "Update
Current Tooling Presets" or "save as Tooling
presets" by clicking the Tooling Presets link.

11.6.2. Create new Tooling Presets from a configured job

To create a new Tooling Preset from a job, you first open a representative job with Layers and
tools.

When job is opened, you set up Layers, tools

and make the job Ready for Production.

Use Advanced > Manage Presets > Save as

Tooling Preset to save the Tooling Preset.

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Another option to save the Tooling Preset is
via the Layer selection Tooling Preset->Save
as Tooling Preset…

The Save As Tooling Preset wizard starts.

Step 1 Press Layer Type to change the name.

When you have correct settings, press Next.

step 2 Assign the material(s) and material

families to the Tooling Preset using the Add
and Remove buttons.

Press “Add” gives next window where you see

the list of all Applicable Material Families or
Materials. In this example we select among
available Materials, which means the Tooling
Preset is not going to be used by all Materials
in the corresponding Material Family.

Note: If you still not have defined the

material of family to be used, you can make
this change later in Resource Manager.

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Press “OK” and you will see that the material is

assigned.

Press Next when you have completed

assigning materials or Material Families.

Step 3 Assign a new unique name for your

Tooling Preset.
A tip is to use a name is descriptive for your
specified production.
Name the Tooling Preset and press “Finish”
completing the wizard.

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The Tooling Preset is now available and can
be viewed and changed in the Resources via
Advanced > Resources… > Tooling Presets.

Add a description to the Tooling Preset if you

want additional information visible for the
operator.

11.7. Setting up Optimization Presets

Optimized Presets define how curves will be

optimized to have the best production.

iPC is delivered with a number of factory

default Optimization Presets. Most of the
curve optimizations can be handled by one of
the factory default presets.

If you need specific settings for curve mappings (not part of the factory presets), you can copy
the preset that is most like what you need, and then make your update.
1. Select preset
2. Press Copy
3. Name your preset
4. Make your update
5. Press OK
More information about how to configure Optimization Preset is available in the iPC User
Manual.

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11.8. Setting up Production Presets

Production Presets describe how the Job

is produced on the table: the Job position,
whether step and repeat is used, how
Registration Marks are found and how the
material is handled.

In the Resource Manager, you are not able to

make any changes to presets.
You can view settings and Rename or Remove
the preset.

Note: The option to remove a preset is only

for presets that are currently not assigned.

You create a new Production Preset from the

Production Tab.

Information that is part of the Production

Preset are:
• Copies

• Quality

• Material Handling

• Registration

• Position

• Step & Repeat

• Tool Head Parking

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When you are ready with your settings, select
Production Preset > Save as Production
Presets....

Name the Production Preset with a unique

name and press Save.

Another way to save the Production Preset is

via Advanced > Manage Presets > Save as
Production Preset…

11.9. Setting up Cutting Profiles

Make your fully defined cutting profiles here.

Cutting Profiles control the whole production:
tools and their settings, optimized curves and
a complete table setup.

The Cutting Profile is a combination of presets

for:
• Tooling Preset

• Optimization Preset

• Production Preset

Cutting Profiles are used in two separate situations.

1. When several materials can utilize the same combination of Tooling Preset, Optimization
Preset and Production Preset.
2. When the upstream application (Device Manager, ArtiosCAD, i-cut Layout) sends a .JDF file
with a Cutting Profile.

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The available settings are:

• Add
• Remove
• Rename
• Copy

NOTE: Remove option is only available for

non-referenced Cutting Profiles.

Press Add to add a new Cutting Profile.

Name the Cutting Profile and press OK.

You can edit and update the Cutting Profile

via:

• Description – Description of the Cutting

Profile
• Tooling Preset – Tools and Layers
mapping

• Optimization Preset – Optimization of

curves
• Production Preset – How to Produce

11.10. Setting up My Materials

Define your materials here in order to

automate your Workflow.
For each material you can select your favorite
way of cutting the material.

Material is a very central part of Resources.

It can be directly referenced to a Tooling
Preset or a Cutting Profile preparing for
minimized operations prior to producing a job.

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The available settings are:

• Add
• Remove
• Rename
• Copy

NOTE: Remove option is only available for

non-referenced Materials. If you remove a
referenced material you get this window.

Press Add to add a new Material.

Click Add to create a new Material in the

Resource Database and fill in the following
information regarding the material properties:
• Material Name – Give a proper name that
you associate with your production
• Material Family – Select a Material Family
(This is a grouping of materials that are
similar)
• Thickness – Enter the thickness of the
material

Note: The combination of Material Family and

Thickness defines which Tooling Presets are
applicable.

The material is now added and you can make

some additional settings under the tabs
General, Cutting and Sizes.

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Note: If you are preparing a new setup, you can come back later to complete the information
in these tabs.
Typically when you have created your own Tooling Preset, Optimization Preset and Production
Preset.

General

• Option to change the Material Family and

Thickness
• Set one of the option of Appearances:
- Default
- Woven Textile
- Grid pattern
- Flexo
- Low Contrast
- Low quality print
• Set the Material Measurement:
- Optimized measurement
- Measure at Laser position
- Do not measure, use specified setting
(Thickness from file is used, e.g. Flexo
materials)
• Set Extra tool lift if it's an uneven material

11.11. Setting up Material Families

The description of Material Families is

displayed when you hoover the cursor over
the Material Families icon.

Material Family is a grouping concept for

several materials that are similar.
Most common Material Families are already
defined in the Resource Database by Esko.

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You need to add the Materials you use to the
Resource Database and map them to the
Material Family that best suits your Material.
If the Material Family you need does not exist,
you can create your own Material Family.

The available settings are:

• Add
• Remove
• Rename
If you need to add an addition Material Family
you press “Add”.

Name the new Material Family and press “OK”.

The Material Family is now available and can

be used for grouping your materials to one
family.

11.12. Setting up Mapping Presets

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Mapping Presets translates your customer’s

files into Layers with standard Layer Types
so that different tools and tool parameters
can be applied for all operations using Tooling
Presets.

Esko provides default Mapping Presets.

For specific needs, it is possible to add Mapping Presets that correctly maps the design curves
into iPC. A Mapping Presets includes Mapping files for each file format. You can set up your
own bundle by selecting the preferred Mapping files for your Workflow.

The available settings are:

• Add
• Remove
• Rename
• Copy

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Create your own Mapping via “Add” (or “Copy”
of an existing Mapping).
Name the new Mapping and press “OK”.

Missing technical lines can be added into a Mapping file.

The available options are:
• Add
• View / edit
• Copy

1) Use an available Mapping for a specified

file type (example ARD).

2) Create your own Mapping for a specified

file type (example PDF). Use add or copy.

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Name the new Mapping and make the

settings you need. Add any technical line you
might need and define the correct Layer type
to be able to use it for Tooling Presets.

Example:
You are using a spot color as a technical line with the name "Drill holes" in your Workflow.
This doesn't exist in the PDF Mapping and need to bee added to the Mapping file.
1. Create a new, make a copy or edit a Mapping file by clicking the settings button
2. In the dialog click add to insert a new line type
3. A new line are added to the list, modify the settings; write "Drill holes" under color, set the
desired iPC layer name and select a layer type that fits that technical line
4. Press OK and make sure this new Mapping is selected for your default Mapping Preset

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11.13. Working with Submit Folder

With iPC you can directly import files in to the Job queue using the “iPC Submit folder”. iPC
will automatically detect files that is dropped in the “iPC Submit folder” and apply settings
according to the file information.
JDF demands you to drop files in to this folder.
Default submit folder
C:\Users\Public\Documents\Esko - Drop files here

Note: The Submit folder can be set in iPC via Edit > Options… > Connection.
The folder needs to be shared within the network to be able to reach it from other computer
and software (ArtiosCAD, Device Manager)
If you have more then one Cutting Table, make sure that each machine has a unique name.

11.14. Migration

11.14.1. Convert Cutting Keys to Tooling Presets

Note: This option should only to be used for system that is upgraded from previous version and
have customer specific Cutting Keys defined with Layer Types.

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Before you make conversion of your old Cutting Keys to Tooling Presets, you should make
sure that you remove all Cutting Keys that you do not use.

Open Cutting Key Manager in iPC via

Advanced > Migrate > Manage Cutting
Keys… .

When the Cutting Key Manager is opened,

select all Cutting Keys you want to remove.
Press the “Delete” button.

Note: Select and delete Cutting Keys is

only needed if not made correctly in the
preparation step (6.5.1)(6.5.2).

Press “OK” to save Cutting Keys to use.

Now you only have the Cutting Keys you want
to convert to Tooling Presets.

Note: Before you make the conversion, make

sure that you have no jobs opened.

Use Advanced > Migrate > Convert Cutting

Keys to Tooling Presets to make the
conversion.

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The Cutting Keys can now be found in Tooling
Presets.

Note: Tooling Presets are listed in alphabetic

order.

Image show one of the Tooling Presets

converted.

11.14.2. Use i-cut vision Cutting Keys and prepare as Tooling Presets

1 - Save i-cut vision Cutting Keys

Before you move to iPC, you need to make some preparations steps in i-cut Vision.
Save the Cutting Keys you want to transfer to iPC with the following steps.
a - Open i-cut Vision
b - Delete unused Cutting Keys

Click File > Maintain Cutting Keys > Cutting

key Manager

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Select all unused Cutting Keys and click the

Delete button

c - Export the Cutting Keys to a location

reached by the new PC, or a on a memory
stick.
Click File > Maintain Cutting Keys > Cutting
key Manager

d - Select all Cutting Keys and click the Export

button

Save the exported xml file on a memory stick,

a network drive or somewhere else they can
be reached from the new PC

2 - Importing i-cut vision Cutting Keys to iPC

Import your i-cut Vision Cutting Keys to iPC as the first step in the migration.

a - Open iPC
b - Import the library from i-cut vision

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Advanced > Cutting Keys > Manage

• Click the Import button

• Leave the Cutting Key Import option on

Replace Library
• Browse to the i-cut Cutting Key Export xml
file
• Click OK and close the manager.

3 - Convert i-cut vision Cutting Keys to iPC Cutting Keys

Open Cutting Keys PRM files and add Layer Type.

To get the old Cutting Keys to work, you need to add Layer Type to each Layer included in the
Cutting Key.
The easiest way to do his is to open all PRM files

a - Make sure “My Job list” is Empty

b - Open Windows Explorer and navigate to
C:\Esko\IcutProductionConsole\IcutEngine\ProgramData\Cutting Keys

You will see one folder for each material you

have in your configuration.

c - Enter .prm in the search window

d - Drag and Drop the files to “My Jobs" list.

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e - NOTE: When you drag and drop a folder

with many Cutting Keys, the Explorer will
prompt a warning message that you "-are
about to open xx files…" :

The message box may be hidden behind the

Explorer window.
You must click somewhere in the iPC program
window so this gets on top, then click "Yes" in
the Message box to continue to copy.

The dragging and dropping will add all .prm

files (Cutting Key template files) for each
material into the My Jobs List

f - Open all .prm files one by one

g - Set “Layer Type” for each layer

h - Check settings for each layer (remember

there are some new features you might want
to use, like % for crease)

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i - Save the file

4 - Converting Cutting Keys to Tooling Presets

The next step is to convert your iPC Cutting Keys to Tooling Presets.
To do that, we use the same procedure as you find in Convert Cutting Keys to Tooling Presets on
page 111.

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