Custom Die Cut Products

What is Die Cutting?

Die cutting uses dies to stamp custom shapes out of rubber, fiber, paper, wood, metal, and other flat sheet materials for manufacturing. A die is a specialized piece of metal with a sharp cutting edge used to cut specific shapes out of material. This process is ideal for creating high volumes of identical parts with precision.

Often used in combination with other finishing services, such as lamination, die cutting services are essential for creating a wide variety of products and components. RubberMill is an experienced provider of die cutting services for various industries, and we have the ability to perform an array of cutting methods on different substrates.

Our Die Cutting Processes

Die cutting works best for repeated runs and high-volume production due to the initial tooling costs of die creation, which can be expensive.

RubberMill has continually focused on developing our die cutting capabilities for flexible materials. We have capability in belt feed, auto-travel, die-less knife, and rotary processes and can cost effectively supply OEM and Automotive Tier suppliers with gaskets, insulators, packaging, etc.

We are able to cut parts up to 80” x 60” from all types of elastomeric and nonwoven sheet or roll stock. And, we are able to respond quickly to customer development and production requirements by building most dies in-house using customer AutoCAD files or recreating from customer supplied dimensional drawings.

RubberMill can construct consolidated or laminated substrates from different facings and materials using various film or web adhesives, or add pressure-sensitive adhesives (PSA) to allow for peel-and-stick functionality, then die-cut these to customer specifications. We perform the following die cutting processes:

1). Flatbed Die Cutting

This is also referred to as steel rule die cutting. A flatbed die cutting press can cut over 2 inches thick during product processing thanks to its ability to exert high pressures. Using a hydraulic or mechanical press, a die raw material between the two surfaces. The cutting die then raises and ejects the finished parts, which are typically carried away by a moving conveyor belt to the packing area.

Cutting dies can be constructed with multiple cavities, with parts oriented to provide maximum material utilization. This process is best suited to softer materials and is ideal for medium-large production runs or larger parts.

2). Rotary Die Cutting

This manufacturing process performs rapid material cutting since you can feed the press an entire roll of material. It utilizes custom-built cylindrical dies that cut various shapes and designs. Stock material travels through the cutting assembly which uses rotary dies attached to a rotary press and a cylindrical anvil. The rotating cylinders pierce the material as it passes through.

Rotary die cutting can be used to produce “kiss-cut” parts, where adhesive-backed material is used to place finished parts. The cutting die cuts completely through the part material, but leaves the adhesive backing liner intact to present cut parts on a roll or sheet for easy removal and installation. Excess trim waste is removed, leaving parts neatly oriented on a sheet or roll of lining paper or film.

3). Dieless Cutting

Often manufacturers need to qualify production part design prior to high-volume die cut production. Utilizing electronic CAD part designs, modern dieless cutting machines provide a means of quickly creating prototype parts of the appropriate dimension and material in the design phase. Dieless cutting also offers an excellent alternative for low-volume or complex component creation.

Materials Used in Die Cutting

Material selection and reliable sourcing of roll and sheet stocks for custom engineered parts can be a challenge. The options and sources are almost endless and the manufacturing landscape is ever changing. RubberMill can help identify appropriate materials and sources during the product development process and can build prototypes using a variety of materials such as nonwoven polyester, closed-cell or open cell sponge rubber, elastomeric blends, silicone or neoprene rubber, polyethylene foam.

We can also construct laminated or consolidated substrates from different materials and facings using various web or film adhesives, or simply add a pressure sensitive adhesive (PSA) for a peel and stick requirement, then die cut these to your specification. Find more information about our custom die cutting services here, or contact us today to speak with a representative.

Examples of Die Cut Products

Die cutting is essential for many applications because it gives a perfectly cut part of a fabric, felt, plastic, rubber, or various other substrates. Die-cut products include but are not limited to the following list:

Industries Served By Die Cutting

Die-cutting processes have enabled manufacturers to operate on many types of non-metallic materials to build identical products quickly, efficiently, and at competitive costs. Production of a broad variety of products from many different materials has been simplified and standardized by using this technology.

Here are some common industries served by die-cutting:

Automotive

Many critical automotive components are produced using die cutting methods. Die cutting allows automobile manufacturers to achieve uniform, tight-tolerance parts that meet industry standards. Common automotive parts manufactured using die cutting include high-performance gaskets and seals, vibration and shock-damping solutions, insulation panels, and more.

OEM

OEMs rely on die cutting services for many reasons. Die cutting is extremely versatile and allows for design adjustments without incurring significant additional tooling expenses. The manufacturing method is also cost-effective and has low setup costs. OEMs in virtually any industry can benefit from die cutting.

Appliances

Every appliance in your home has die-cut components. With the appliance industry’s rapid growth, appliance manufacturers need a fast, cost-effective method to produce large volumes of identical parts. From gaskets, seals, spacers and films to insulation, die cutting is essential to the appliance industry. Often, the die cut parts are provided with pressure-sensitive adhesives for quick installation in the manufacturing process.

Transportation

Die-cut parts are used in many applications throughout the transportation industry in buses, trucks, emergency vehicles, heavy equipment and rail. Gaskets, seals, spacers, filters and insulating components are some of the many applications where die cut parts are utilized. Fuel systems, cooling systems, HVAC, and even braking systems employ die cut components.

Recreational

In the manufacture of watercraft, motorcycles, camping, and off-road vehicles, die cut components help manufacturers ensure a reliable, cost-effective means of producing necessary parts for production. Specialized materials can be die cut to provide durable fuel, oil and water-resistant components as well as other functional and aesthetic parts. Common parts include seals, gaskets, and various foams for durable solutions to the tough environmental conditions to which these devices are commonly subjected.

HVAC

Die-cut parts are found throughout industrial, commercial, and residential heating, air conditioning, and ventilation systems. Common HVAC parts manufactured with die cutting include seals, gaskets, sound and vibration dampeners, insulating components, and more.

Electronic and Electrical Industry

In the electrical industry, there is a requirement for economical fabrication amplified by the demand for battery packs, small electronic appliances, and critical environmental control for energy storage, data and communication facilities. Die-cutting allows for the creation of weather-tight sealing systems, high-voltage isolation, motors, coil insulation, noise dampeners, flex circuit components, etc.

Die Cutting Services by RubberMill

RubberMill has a continual focus on improving our die-cutting services. We continually invest in the latest technology to ensure the highest quality and cost-effectiveness. Partnering with an experienced die-cutting service provider will ensure your finished product is defect free within demanding cutting tolerances.

RubberMill will help you select the right materials during the product development process and then build prototypes using any of our available materials to qualify the component parts. Contact us today for more information.