Custom Die Cutting Process

Our custom die cutting process begins with slitting. The materials we use—adhesives and substrates—come to us in four to five-foot wide master rolls. Prior to die cutting, the rolls of materials must be slit into smaller, more useful dimensions. Then the substrate material and adhesive are laminated together.

Slitting

We use two types of slitters to prepare your materials, which one used depends on the specific process and end product.

Rewind Slitter – The rewind slitter mechanically unwinds the master roll, slits the material to the proper width, and automatically winds the slit material onto narrower rolls for further processing.

Single Knife Roll Slitter – This computer controlled slitter precision cuts stock from the master roll without rewinding. Capable of slits smaller than .2 inches, while holding to very tight tolerances, the single knife roll slit material is precise enough to be sold directly to our customers.

Laminating

Laminator/Slitter – Depending on the product and its application, we may be able to slit and laminate substrates and adhesives simultaneously, reducing your cost and the time it takes to process the product. Using our temperature-controlled, heat assisted laminator, we can laminate rubber or acrylic-based adhesives to a variety of flexible materials.

Die Cutting

Die cutting is the next step in the process of producing your product, wherein the adhesive backed material is shaped to meet the needs of your application. Individually die-cut pieces can be presented on continuous rolls (rolled with the parts inside or outside) or they can be bulk packed.

The two principal technologies we employ are Rotary and Steel Rule Die Cutting.

Rotary Die Cutting – Allows for greater production speeds and efficiencies relative to other types of die cutting. Waste and holes can normally be removed "in line," decreasing cost. Finished parts can usually be presented on rolls, and part size is generally limited to 16" x 30" and thicknesses up to .25"

Steel Rule Die Cutting –Accomplished with flatbed presses, accommodating larger parts (up to 27" x 50") with thicknesses up to 2.0". While rotary is a faster process side-by-side, our expertise helps accelerate the pace of steel rule die cutting. For example, we present product to the presses on rolls instead of sheets. For your custom project, the slower cutting process is made up for by the speed with which steel rule dies can be developed.