Die-Cutting

Die-cutting is a valuable production process that is often used to mass-produce large quantities of identically-shaped parts. It is a process that involves stamping or cutting thin materials such as plastic, foam, metal foil, thermal insulation, and fabric using specialized machinery and tools known as dies. To help you better understand the die-cutting process, we have compiled a list of the most commonly used die-cutting terms. This list will give you a better idea of what to expect when it comes to die-cutting.

Flatbed Die-Cutting

Flatbed die-cutting is one of the oldest and most traditional forms of die-cutting. It involves cutting or perforating a two-dimensional shape out of a thin, flexible or semi-rigid material using a hydraulic flatbed press and die. The dies used by professional die-cutters are called steel rule and consist of blades and punches formed into the shape of the final part and fastened into either a flat piece of wood or steel plate. Compared to the rounded cuts produced by rotary die-cutting machines, the flatbed die-cutting process results in much sharper and crisper cuts that are performed perpendicular to the die bed. This allows for cutting parts from a wide range of material widths and thicknesses. Additionally, steel rule dies are easier to change out and more efficient when cutting multiple shapes.

Rotary Die-Cutting

Rotary die-cutting is a great solution for those looking for accuracy and consistency in quickly producing large volumes of parts with tight dimensional tolerances. The process is quite different from flatbed die-cutting, which uses a flat die to stamp out shapes. In rotary die-cutting, a cylindrical steel die is rolled over the material, similar to a rolling pin with a built-in cookie cutter. The material is fed into the press’s die-cutting station which contains a cutting die cylinder and a hardened anvil cylinder rotating in opposite directions. As the web passes through the cutting station, the cutting die’s edge compresses the material against the anvil until it cuts through. Furthermore, rotary die presses can be set up with multiple stations to enable in-line operations such as lamination, through-cutting, kiss cutting, scoring, and sheeting, eliminating the need to complete separate steps.

Kiss Cutting

Kiss cutting is an incredibly versatile die-cutting process. It gets its name from the blade or steel rule die that lightly ‘kisses’ the release paper backing without cutting through it, resulting in a die-cut part that is not fully separated from the stock material, but can be easily removed. This technique is commonly used to cut stickers, labels, and other adhesive-backed parts, and can be presented on a roll with the waste/matrix material either removed or left in place. To further minimize mess on the assembly floor, kiss cutting can be combined with through cutting. Compatible with a variety of materials like foams, rubbers, foils, papers, vinyl, and more, kiss cutting is a great option for many applications.

Butt Cutting

Butt cutting is a useful process that helps to minimize waste material and maximize the size of the parts being created. It is a term that refers to the cutting of individual parts so that they fit together without a gap between them. This technique is commonly used for adhesive-backed parts, as it allows for the production of the largest possible parts within the available dimensions of the laminate. Additionally, butt cutting can be used to cut sheets of parts or to create cuts between rectangular parts that are kiss-cut to their liner backings. In sum, butt cutting is a useful tool that helps to maximize the size of parts while minimizing wasted material.

PSA

Pressure-sensitive adhesive (PSA) is key for many projects. PSA is a type of non-reactive adhesive that adheres to a substrate when pressure is applied – think of Scotch tape, bumper stickers, and Post-It Notes. SpecTape laminates PSA to materials such as foam, metal foil, insulation, and even thin plastics, to provide parts with an adhesive backing. It’s important to keep in mind the amount of pressure used to apply the adhesive to the surface, as well as surface characteristics like smoothness, surface energy, and removal of contaminants. Generally, PSAs are designed to form a bond at room temperatures, but some may lose their tack at lower temperatures, and reduce their shear holding ability at higher temperatures. Special adhesives are also available for extreme environments.

Scoring

Scoring is an effective technique, found in everyday life, for creating parts that can be folded or formed into three-dimensional shapes for assembly. The score itself is a single stress point, where the material is partially cut, usually no more than 50% of the material thickness, to avoid weakening the material to the point of breaking or tearing. One of the advantages of scoring is that it allows for the formation of true square corners or bends in the final part. For example, the next time you purchase a greeting card, take a look at the spine and you will likely see the score which has allowed for the card to fold neatly.

Lamination

Lamination is a very useful process often used in a wide range of applications. It involves joining two or more materials together to form a single composite material. The advantages of lamination are plentiful, offering improved physical properties like stability, strength, and insulation from heat and sound. Additionally, lamination can be used to create materials of custom thickness. For instance, we can laminate PSA backing to foam rubber, two pieces of insulation together for heightened heat resistance, or aluminum foil, ceramic insulation, and a PSA backing to make TAB shield peel-and-stick heat thermal acoustical barrier. Lamination is a versatile and beneficial process with a multitude of applications.

Yield

At SpecTape, we understand the importance of yield when it comes to die-cutting custom parts. Yield is all about getting the most out of your raw materials without sacrificing part quality, which can make up to 75% of the total part cost. That’s why we strive to maximize part yield from the raw materials we use, so that we can offer our customers the best parts at competitive prices. Our commitment to yield ensures that our customers are getting the most out of their money while still receiving quality parts.

Pull-Tab

At SpecTape, we understand the importance of minimizing effort and time in the assembly process. To help customers save time and reduce tedious work, we offer pull-tabs as an alternative to traditional die-cut parts with adhesive backings. Our high-speed rotary presses are capable of producing pull-tabs with a small, overhanging piece of release liner on one edge, allowing the liner to be easily removed with a single pull. This pull-tab feature can be a major time-saver, especially when dealing with high volumes of labels or gaskets.

Let Us Help!

When it comes to custom die-cutting, SpecTape is the top choice for a reliable, knowledgeable partner. We not only provide top-quality parts made to your exact specifications, but we work with you from concept to mass production and beyond. With access to the world’s best specialty materials and our expertise in the field, SpecTape is your go-to choice for custom die-cut parts. So if you have a challenge that needs a solution, let’s have a conversation about how SpecTape can help.