.png)
No time to read the entire guide now?
Not a problem! Enter your email below and we will send you a downloadable PDF version that you can get to on your own time.
What is Die Cutting?
A tailored die cutting service from an experienced contract manufacturer will quickly and precisely shape materials and specialty fabrics with repeatable accuracy, typically within a 0.01-inch cutting tolerance, without ever sacrificing quality or performance.
Manufacturers and businesses in any industry requiring high volume manufacturing can leverage advanced die cutting to precisely cut uniform shapes. Industries such as aerospace, automotive, and medical are examples of the many industries that rely on extremely precise custom die cutting to provide high-quality results while maintaining regulatory compliance.
The extensive benefits that die cutting processes offer have resulted in die cutting becoming the industrial standard for the production of certain products such as washers, optical films, insulating foams, medical equipment, and vehicle components. In addition to the manufacturing of certain industry products, advanced die cutting processes can be leveraged for a variety of use cases including:
- Composite cutting
- Custom pattern cutting
- Carbon fiber cutting
- Ply cutting
- Leather cutting
- Foam cutting
- Kevlar cutting
- Rubber cutting
- Plastic cutting
- Fiberglass cutting
- Urethane cutting
- Membrane cutting
Die Cutting Methods
.png)
Manufacturers and businesses can partner with the right custom cutting service provider to leverage any of the main die cutting manufacturing processes to quickly and efficiently shape and cut a range of varying materials.
Flat Bed Die Cutting Process
The flat bed die cutting process, also referred to as steel rule die cutting, is a fabrication process that utilizes a flatbed die cutting press and steel dies to cut raw materials into custom shapes and designs. This specific type of die cutting process is most suitable for custom cutting projects processing thicker materials (over ⅛ inch) as it is capable of exerting high pressures.
Rotary Die Cutting Manufacturing Process
The rotary die cutting manufacturing process leverages a rotary die press and custom-built cylindrical dies. This manufacturing process enables rapid material cutting as an entire sheet or web of raw materials can be fed into the press at one time. Once the machine is loaded, various shapes and designs can be cut.
What is Waterjet Cutting?
.png)
Waterjet cutting is an extremely versatile precision cutting service that can be used in a wide variety of industries for intricate designs and precision cutting jobs that require high tolerances. Waterjet cutting tables have a fast-set up time and can cut a wide range of materials without Heat Affected Zone (HAZ) or leaving heat-hardened edges. Due to fast programming and set-up times, waterjet cutting tables are great for creating prototypes and for short-run precision cutting projects.
From precision to fast cutting speeds, here are the characteristics and advantages associated with advanced waterjet cutting tables.
Waterjet Cutting Methods
There are a variety of cutting methods associated with waterjet machines that businesses can leverage depending on their particular precision cutting needs.
- Pure Water Cutting - Pure water cutting is most suitable for cutting soft materials such as food, foams, papers, or plastics. The process is extraordinarily environmentally friendly because its main byproduct is pure, recyclable water.
- Abrasive Water Cutting - Abrasive water cutting is defined by the mixing of a hard, powdery material into the water jet such as garnet or corundum to act as an abrasive agent. This process is more suitable for hard materials such as metal, marble, and composites.
- Cold-Water Cutting - This process offers precise cutting without the detriment of a heat affected zone (HAZ). The no heat technology of waterjets allows for no part distortion, thermal damage, or stress damage to the finished product. The inclusion of cold water also enables clean cuts and increases the operators’ safety by eliminating the risks of burn damage.
- Low-Pressure Pierce - This waterjet cutting method helps prevent material from cracking by operating on low pressure. This process is more suitable for brittle materials like glass, stone, and ceramics.
- Wiggle or Dwell Piercing - Wiggle piercing, also referred to as dwell piercing, is a method in which water jet streams move repetitively across a very short distance to precisely cut the material. This process is suitable for making holes in thick materials.
What is CNC Cutting?
.png)
From complex shapes to one-off production runs, computer numerical control (CNC) static cutting table systems provide manufacturers a versatile and cost-effective cutting solution with superior advantages over manual cutting processes.
Original Equipment Manufacturers (OEMs) and businesses should understand what CNC cutting is and the benefits of using automated CNC static cutting tables so they can identify a contract manufacturer that has the resources and cutting capabilities to ensure their needs are met with pinpoint precision.
CNC cutting, or CNC machining, is a widely used automated manufacturing process that utilizes computerized controls to operate and manipulate cutting tools such as drills, lathes, and mills to shape stock material into custom parts and designs without the need of a manual operator directly controlling the machine. CNC cutting relies on digital instructions made on Computed Aided Manufacturing (CAM) or Computed Aided Design (CAD) software.
Automated CNC cutting machines cut with accuracy, repeatability, and are available in a range of lengths and widths to accommodate a wide variety of designs. There are two main types of automated CNC cutting systems - static and conveyor - both with unique advantages and disadvantages depending on the cutting project. Static cutting tables are durable and easy to use, while conveyor cutting tables are generally more expensive, use complicated software, and require frequent maintenance.
While waterjet cutting excels at cutting metals and thicker materials, automated static cutting tables are fabric-based and excel at single to low-ply cutting. OEMs and businesses that need to cut complex shapes for smaller production runs can avoid die cutting and custom die by leveraging automated static cutting tables.
What is Laser Cutting?
.png)
Laser cutters create patterns and designs by using a powerful, 5 micrometer laser beam to cut melt, burn, or vaporize materials. This thin, focused, laser beam can either cut or etch materials under +/- .25” into custom designs, patterns, and shapes as specified by the designer. Given a .dxf file with the needed shape, OEMs can automatically arrange an arrange of those shapes to be cut at once. This laser cutting process is ideal for several materials, including rubber, polyethylene foam, TPO roof membrane, nylon webbing, acrylic, wood, fiberglass fabric, metal, plastic, and gemstone.
Today, laser cutting is used in industries such as aerospace, automotive, electronics, and medicine. One of the most common applications is for cutting fabric because of the lasers’ ability to deliver clean cuts and smooth finishes. Because the laser does not physically touch the material being cut, there is no distortion or pulling. It leaves a melted edge that will prevent fraying, which is particularly beneficial on webbing and fiberglass fabric.
Are you ready to take the first step to streamline your production process?
Talk with a Custom Cutting Specialist.
