Archive: Nov 2023

The Industrial Flatbed Lamination Process

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Flatbed lamination is a process that involves using pressure and heat to join multiple materials, producing a multi-layered composite with improved properties. Compared to PSA lamination, which involves creating a sticky, adhesive surface to bond materials with, industrial flatbed lamination can create specialized laminates such as multi-layered sheets or rolls.

Industrial flatbed lamination is used across diverse industries for applications such as automotive components, packaging, insulating panels, and molding precursors. This process not only produces a high-quality finish but also can improve the appearance of products, add a protective barrier, and to reduce material thickness when desired.

The Basics of Industrial Flatbed Lamination

Flatbed lamination is used to combine different materials such as foam, film, fabric, and nonwoven materials to produce a composite material with improved characteristics. The main goal of industrial flatbed lamination is to create materials with highly specialized properties, such as enhanced structural integrity or insulation.

This process is especially beneficial for creating products with a smooth, level surface from raw, uneven substrates. As such, it allows for the use of more economical materials compared to other lamination processes. Flatbed laminators also facilitate precise thickness reduction and material densification of certain foams, nonwovens, and other substrates.

Depending on your particular needs, the adhesion between the materials being laminated can be achieved using thermoplastic adhesives in the form of webs, powders, and films. Some materials can even be laminated without the need for additional adhesives due to their inherent thermoplastic characteristics.

Types of Industrial Lamination at RubberMill

At RubberMill, we utilize highly advanced Pressurized Flatbed Laminating technology that employs zoned heating, cooling, and pressure to produce unique material composites. Using a range of material combinations as well as adhesive films and webs, we can create the desired end product. For example, we can combine nonwoven materials with films or fabric with foam.

If the main goal is the application of pressure sensitive adhesives, RubberMill also offers PSA lamination services using dedicated equipment. The finished PSA laminated product can be converted into continuous rolls of stripping or cut into separate parts.

With over three decades of industrial lamination expertise, RubberMill can deliver innovative solutions to meet the needs of various industries and applications. This level of experience allows us to provide finished laminated products that adhere to specific OEM requirements.

The Technology Behind RubberMill’s Lamination Process

Our advanced belt press lamination machine uses a horizontal flat conveyor run, allowing it to accommodate materials of various thicknesses and widths. By applying customized amounts of pressure, heating, and cooling, our machine enables precise control over the properties of the end product.

To meet the needs of sensitive applications, RubberMill’s lamination process includes continuous full-width thickness monitoring, including product-specific settings that can be stored electronically for the duration of the laminating process. Our machinery is also capable of creating sheets with specific dimensions and can automatically trim the edges to ensure uniform roll width.

Our lamination technology is highly cost-effective due to its high speed and minimal energy and adhesive consumption. This makes it a sustainable option for all of your industrial lamination needs.

Benefits of Contract Lamination with RubberMill

By outsourcing your industrial lamination needs to RubberMill, you gain access to the following benefits:

  • Cost savings.Outsourcing your lamination process reduces costs associated with investing in additional machinery and manpower.
  • Speed. Our level of expertise ensures a fast and efficient manufacturing process. This results in a quicker time-to-market for your laminated products.
  • Turn-key. Our in-house die-cutting capabilities allow RubberMill to provide a turn-key lamination solution. This eliminates the need for you to transport your laminated materials for further converting.
  • Eco-friendly. Industrial lamination is a more environmentally friendly alternative to flame bonding and other lamination processes that emit toxic fumes.

Take Your Industrial Lamination to the Next Level: Contact RubberMill Today

Contract laminating helps companies save significant amounts of time and money on specialized material finishing processes they’re likely unequipped for. At RubberMill, we offer contract flatbed lamination and well as other lamination services to deliver the unique composites you need. For more information about our industrial lamination capabilities, or to get started on your contract laminating solution, request a quote from us today.