Die Cutting Services

Die cutting services use a variety of die cutting methods to fashion materials into predefined shapes or sizes.  Several different types of die cutting are available, including flat and rotary laser die cutting, blade type rotary die cutting, steel rule die cutting, and ultrasonic die cutting.  The method used can vary, depending on such factors as material, and end product configuration.  Laser, or laser die cutting is performed on computer controlled, 3-axis laser cutting machines.  Laser cutters can be used to cut materials that cannot be cut using conventional steel rule die cutting, such as steel to over .500".  Laser cutters are available in flat and rotary configurations.  Flat laser cutters are used to cut flat sheets of material and rotary laser cutters cut material from roll stock.  Rotary die cutters cut and score soft to semi-rigid material by forcing it between the blades on a cylindrical die and a hard cylindrical anvil.  Rotary die cutters are primarily used to cut material from a web (continuous roll), although they can be used to cut material in sheet form.  Steel rule die cutters score and cut material into various shapes, as determined by the steel dies.  Examples of products that are die cut are flat gaskets, puzzle pieces, and a presentation folder that has a pocket (the pocket is scored, folded and glued).  Steel rule die cutters can cut sheet material or material from roll stock.  Ultrasonic die cutters use vibrations applied at ultrasonic frequencies to cut or seal a material.  The vibrations cause heat and pressure to be generated, which causes sealing of thermoplastic materials and cutting, depending on the blade configuration.

Many different materials can be processed by suppliers of die cutting services for a wide variety of applications.  Materials include felt, fabrics, fiber or cork or paper, metals and alloys, plastics, rubber, foam and sponge, composites, electrical insulating materials, and EMI/RFI shielded foils and laminates.  Examples of products manufactured by die cutting include gaskets and seals, shims, templates, inserts, washers, and puzzle pieces.

Typical services offered by suppliers of die cutting services include CAD / CAM support, design assistance, prototype, short run production, high volume production, and inspection or quality control.  A supplier that has CAD or CAM support has the computer technology to receive solid model files electronically and use those files for part creation.  A supplier with design assistance capabilities can assist with concepts, manufacturing costs, manufacturing techniques and material considerations. Supplier may also be able to assist in upgrading or redesigning, re-evaluating or modernizing existing products to increase performance and/or reduce manufacturing costs.  Prototypes include a prototype or part that will be used in actual functional testing.  Short run production capabilities provide low volumes of product.  Suppliers with high volume production capabilities can provide high volumes of product.  Inspection or quality control services include quality inspection reports or statistical process control data.  Certifications and quality requirements often met by suppliers of die cutting services include ISO 9001, ISO 9002, and QS 9000.

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