What is Die Cutting?
Die cutting is a process that converts stock material into a specific shape or pattern. We at Automated Gasket Corporation use specialized machinery and equipment to cut, form, and shape a variety of materials. If you are looking for reliably accurate cutting for your product prototype design, our gasket fabrication experts can help! All you need to do is provide us with your CAD file, or our CAD expert can draw it up for you if you have a design. With our precise die cutting abilities, we can manufacture your unique product with a quick turnaround.
Contact our qualified team today for a cost-effective die cutting solution!!
Types of Die Cutting
Die cutting isn’t a one size fits all process. Depending on the quantity and type of material your project requires, our gasket fabrication and die cutting experts may recommend one of several die cutting processes.
Steel Rule Die Cutting
Steel rule die cutting (also called flatbed die cutting) involves pressing a sharp steel rule (“knife”) down into the material against a flat surface. The cutting edge pierces the material being converted, separating the part and the waste. While more complex, the process can be compared to a cookie-cutter cutting specific shapes out of cookie dough.
Steel rule die cutting is suitable for a variety of materials, including fabric, fiber, paper, plastic, metal, rubber, foam, foil, composites, and laminates. Compared to other types of die cutting, flatbed die cutting offers several advantages. It is suitable for larger and thicker materials and makes sharper, more crisp cuts with minimal material deformation. Steel rule die cutting is a precise way to cut a material, which produces cuts that are the same each time, within a small margin of error.
Lathe cutting is a suitable option for producing gaskets with either a large outer diameter or a small inner diameter. Lathe cut gaskets are generally the best choice for use in applications that require a static seal. Advantages to lathe cutting include guaranteed parallel cut surfaces, tight dimensional tolerances, smooth surface finish without parting line, and limitless material choices.
Lathe cut gaskets are manufactured through a precision extrusion and curing process with highly automated cutting equipment. After extrusion, the gaskets are cured over a mandrel to assure the inside diameter meets specification and ground to assure the outside diameter also meets specification. The cured tubes are then cut to proper width on lathes (bayonets) that provide precision-cut width with almost 100% of the material used.
Rotary Die Cutting & Kiss Cutting
Rotary die cutting is one of the most common types of die cutting. It is a broad category that includes kiss cutting and other processes that use a rotary press. This precision die cutting method uses custom-made cylindrical dies and a rotary press to convert material from roll stock to a finished device, such as a gasket. A range of materials, including sheet metal, fabric, plastics, and more can be used. The process of rotary die cutting involves a flat material being fed through a die that is continually rolling in place. As the material passes through, a cutting edge pinches the material and pushes out the gasket in its desired shape. One of its main benefits is that it quickly creates gaskets with a high degree of accuracy, in a variety of shapes and is limited only by the size of the roller.
Kiss cutting is a rotary cutting method where the blade lightly cuts through the upper layers of the material, but the back layer is left intact. It requires a laminated material, whether it’s plastic, cork, felt, silicon, or adhesive-backed paper. The main advantage of kiss cutting is its ability to create gaskets that can be easily removed from their backing layer when needed.
Compound Die Cutting
Compound dies produce a complete blank in one station at every stroke of the press. These dies perform one or more operations at the same time. For instance, they can blank (cut the outer form) and pierce (cut the inner form) of a shape simultaneously. As a result, the cut shape will come out of the press in its completed, finished form. Compound die cutting is commonly used for cutting very hard materials like fish paper, plastic, rigid films, shims, fiberboard, and other materials that may not be well suited for other die cutting methods. Advantages include its high degree of mechanical accuracy and ability to cut very intricate shapes.
Cutting by hand is ideal for larger gaskets and low volume requirements. Our team will hand mark out shapes and then use knives and saddle punches to produce your custom hand-cut gasket.
Custom Die Cutting Process
Our in-house tooling, prototyping capabilities, and raw material buying power allow for an efficient custom gasket fabrication process that will yield the best results for your project. The process of die cutting made-to-order gaskets is simple. Send us your CAD file, detailed drawing, or gasket photo, and we will manufacture your custom gasket to fit your specifications, or our CAD expert can draw it up for you if you have a design.
Why Choose Us for Die Cutting Services
When you work with Automated Gasket Corp., you receive the best customer service from our knowledgeable team as well as high-quality results in a timely manner. From gasket fabrication and gasket bonding to waterjet cutting services, we can make the product design and prototyping process easier for you!
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To have your cutting needs handled by our die cutting machine pros, contact us today!
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