User:Plitek

The precision die cutting is the process of using specialized equipment and tools to cut shapes from materials such as foams, films, tapes and adhesives.

There are a few different types of Precision Die Cutting:

Rotary Die Cutting: Rotary die cutting is a manufacturing process used to cut, shape, and form materials using a cylindrical die on a rotary press. The die, which has the cutting pattern, rotates in sync with the material as it moves though the press.

Rotary die cutting stands out for its speed and efficiency making it suitable for large scale manufacturing. Capable of running webs at hundreds of feet per minute, this process excels in removing slugs in line, ensuring continuous, uninterrupted production. Its ability to island place and reduce material scrap makes it an economical choice.

One of the most significant advantages of rotary die cutting is the ability to manipulate tension in webs, allowing us to handle complex applications involving multiple webs, die cutting, and laminating—all within precise registration. Our servo-driven, electromechanical equipment is adept at managing advanced-level components and processes.

Flatbed Die Cutting Flatbed die cutting, or steel rule die cutting, is a process used to cut, shape, and form materials using a flat die on a press. Unlike rotary die cutting, which uses a cylindrical die, flatbed die cutting uses a stationary, flat die that presses down onto the material to create the desired shapes. The material is placed on a flat surface and the die, mounted on a press, moves up and down to cut through the material.

Flatbed die cutting is known for its quick turnaround, making it perfect for projects requiring a faster speed to market. The tools used in this process are generally lower in cost and can be procured within days. This method is particularly effective for larger part sizes and a variety of foams, making it versatile for lower volume applications. While not matching the volume output of rotary die cutting, flatbed die cutting offers a balance of efficiency and cost-effectiveness, especially for projects where ultra-tight tolerances are not as critical.

Laser Cutting Laser cutting is a manufacturing process that uses a high-powered laser beam to cut materials with high precision. The laser beam is directed at the material, melting, burning, or vaporizing it to create clean and accurate cuts. This process is controlled by computer numerical control (CNC) systems, which allow for precise and complex designs to be executed.

Laser Cutting provides a unique value in our precision converting processes. It produces a complex cut with tight tolerances, making it ideal for applications like cutting open-face adhesives or parts that need to avoid re-welding. Its rapid prototyping capability allows for the same-day cutting of parts, offering unparalleled speed to market. We often combine laser cutting with other processes, such as laminating and rotary die cutting, to utilize the best of each method depending on the material and process requirements.

Laser cutting is widely used to manufacture components for aerospace, automotive, electronics, medical device manufacturing, and custom fabrication.