Home > contract manufacturing > Manufacturers – Consider Outsourcing Die Cut Technologies

die cut technologiesCompanies researching the various die cut technologies related to the manufacturing process are probably familiar with the high cost of the equipment involved. Die cutting, depending upon the materials involved, can be a costly manufacturing process. In addition to the equipment, one must consider the trained technicians that need to operate the machinery. Likewise, the operators must have the experience and judgement to handle the particular materials and understand how they fit in as a component of the end product.

Conversion Technologies, Inc. (CTI) offers die cutting services on a contract or toll manufacturing basis. It is one of the services that we provide to companies large and small nationwide.

The Die Cutting Process

Generally, die cutting is a part of the manufacturing process to create a unique shape or pattern in a material, which may either be the finished product or a component of a more complex product.

Die cutting, the process of using a uniquely shaped die to cut through layers of materials to create a finished product, is complex. Overall, it has become more versatile as new materials have come into the marketplace. Additionally, our ongoing technological developments allow us to create more sophisticated products and the machinery must keep pace.

Historically, the die cutting process began with cutting through layers of leather to manufacture shoes. From there, manufacturers of other products realized that the process could work for other materials. Consequently, a series of machines and equipment evolved to the more modern versions that are in use currently.

Products on the Market Today that Require Industrial Die Cutting

Today’s sophisticated marketplace is a constantly evolving selection of new products made with new materials and using new techniques. Die cutting has become a necessary function in the manufacturing process for items including everything from consumer products to airplane parts. Some items include:

Some of the materials that we work with for various manufacturers include:

  • Paper
  • Rubber
  • Felt
  • Chipboard
  • Non-wovens
  • Plastic
  • Silicone
  • Neoprene
  • Rubber
  • Foam

Does CTI Offer Various Slitting and Die Cut Technologies?

We offer flatbed (steel rule) and belt-fed methods of die cutting. Uses for die cutting are widespread, but the die cutting technology is critical to the production of many industrial parts and components for machinery and equipment, in addition to consumer products.

Flatbed die cutting:

This method utilizes a die cutting press and custom dies to create unique shapes from various raw materials. Ultimately, this works best when working with thick materials and producing large finished products. Flatbed die cutting is known for its supreme accuracy with most materials.

With this equipment, CTI has the capability to cut both in sheet and rolled formats. Our clients have come to us with the need for a die cutting service to produce complex shapes using many types of materials. Notably, we built our facility to incorporate only top-of-the-line, precision machinery and equipment. Moreover, the layout of all of our manufacturing areas is specifically flexible due to the modular design. This allows us to quickly change from one type of process to another, without a major re-configuration. Our technicians and engineers have the expertise to solve the most complex issues for our clients and are well-versed in working with a broad range of materials and techniques.

Our capabilities using die cut technologies extend to cutting materials up to 5/8” thickness and sheets as large as 40” x 60” and rolled materials up to a broad 60” width.

Belt-fed method:

When working with continuous rolls or large batches of non metallic materials such as carpet or rubber, the belt-fed method is superior. Our experts will determine the best methods based on the raw materials and the desired end result.

Types of Cuts Used in Die Cutting

Depending upon the materials and the finished product, there are several types of methods used in die cutting.

Perforating

This cut produces closely-spaced holes in the desired pattern, which is the cut we would use when the material needs to detach at some point and retain the desired shape.

Through Cutting

One of the most common cuts and self-explanatory, this cut penetrates through all layers of the material to create a unique shape for a specific product.

Kiss Cutting

When a product has a backing layer of material, kiss cutting slices through all layers except the backing, so that you can detach the final pattern later on from the back layer. Sometimes, that base layer includes an adhesive.

Scoring

Similar to perforating, this leaves an impression at precisely arranged points and cuts through less than half of the layers of material. We use this when allowing for folds in the material.

Creasing

This method creates a fold line on the material, similar to scoring. But, it has a different pattern of fold points.

What is the Best Solution When a Manufacturer Needs Industrial Die Cut Technologies?

Conversion Technologies, Inc. is a national leader in partnering with industrial companies both large and small to provide die cut technologies on an as-needed basis. Working as either a contract manufacturer or a toll manufacturer, CTI can handle die cutting for your company as a unique component of your production line. Or, we can produce the finished product and ship to the next stage in your supply chain.

Today, more companies are learning that the cost of investing in high-end machinery and the staffing to operate that machinery and equipment is a burden to their bottom line. Furthermore, even if you invest in the equipment and operators, you need the physical space in which to perform the operation.

When there is a reputable, reliable contractor such as CTI willing to take on the responsibility of handling that expensive portion of your process, why invest precious cash, physical space, personnel and resources to achieve your goal? Simply, discuss your needs and concerns with the experts at CTI and allow us to save you the valuable resources of time and money.

Additional Services That CTI Offers on a Toll or Contract Basis

As a leading industrial contract manufacturing facility, we offer a full range of additional services to our clients. Our adhesive coatings and lamination services are extensive.

Clients both large and small appreciate the range of capabilities available within our well-equipped facility. By taking advantage of our technical expertise, state-of-the-art equipment and problem-solving methodologies, they realize a fantastic ROI. Savings incurred by the investments that they don’t have to make for equipment, staffing and physical space is a major bonus for their financial planning. Often, they use the savings to provide employee benefits, additional real estate investments, etc., that would not be possible if they had to make those major expenditures.

Coating and Lamination Methods Available

There are multiple die cut technologies available. 

Hot Melt Spray Coating

This method applies molten adhesive through a spray nozzle, creating a strong bond between materials. It is effective for fast curing and robust performance. Common applications include packaging, textiles, and automotive parts that need to withstand environmental conditions.

Slot Die Coating

Slot die coating uses a narrow slot to deliver a uniform layer of fluid material. This precise method achieves consistent thickness. It is suitable for electronics, automotive, and packaging projects, where uniform coating is crucial for performance.

Hot Gravure

This process uses engraved cylinders to transfer heated inks or coatings to a substrate. Hot gravure printing produces high-quality, vibrant images while ensuring good adhesion and durability. It is commonly used for decorative packaging and specialty printing applications.

Roll Coating

In roll coating, substrates pass through rollers that evenly apply coating materials. This efficient method provides consistent coverage across various materials, including paper, textiles, and metals. It is ideal for applications requiring speed and uniformity.

Meyer Rod Coating

Meyer rod coating uses a rod with a specific gap to control the thickness of liquid coating. This technique offers precise thickness control and is suitable for paper and film industries. It produces a smooth, uniform finish on delicate substrates.

Knife-Over-Roll Coating

This method uses a knife blade above a roller to achieve consistent film thickness. Knife-over-roll coating provides high-precision results, making it suitable for coatings, adhesives, and laminates requiring accuracy in thickness.

Belt Laminator

A belt laminator transports materials through the laminating process on a conveyor belt while applying adhesive layers. This method is efficient for continuous, high-volume production and accommodates various materials and thicknesses. It’s commonly used for composites and packaging.

Hot Roll Lamination

This technique uses heated rollers to apply adhesive layers between substrates. Heat and pressure create strong adhesion, making it ideal for durable applications such as laminated documents and protective packaging. Hot roll lamination is appreciated for its efficiency and robust finishes.

Industries That CTI Serves

  • Automotive
  • Aircraft
  • Furniture
  • Roofing
  • Textiles
  • Consumer Products
  • Construction
  • And many more!

Do You Need to Test a New Product or Material?

We offer a unique resource to our clients…a complete research and development facility with fully-trained technicians and cutting-edge equipment. Many companies, even if they can afford to have an R&D department, may not have the space for it. Additionally, they may not need the same equipment for all testing, or may only need a lab at certain intervals. However, there is no need to make a large investment in a research facility, when we maintain one and it is always available for our clients’ projects.

Since our goal is to put our clients ahead of their competition, we are proud of the new and improved products that result from this facility and its innovative staff. By having experts available for consulting and advice, our clients have a distinct advantage cost-wise.

Case Studies

Some of the leading manufacturers in the country have taken advantage of our problem-solving methodologies. In case after case, we have resolved manufacturing issues that they thought were dead ends. Feel free to review some of our examples.

Clients

As we mentioned, our client base extends from small, local companies to national brands. All take advantage of our expertise, top-quality equipment and work ethic to help them achieve success, no matter their industry. A few of our well-known clients include:

  • Hanesbrands
  • Uniroyal
  • Owens Corning
  • Ford
  • Clorox
  • Firestone
  • Sauder
  • Henkel
  • Kimberly-Clark
  • Steelcase
  • Lear

Our 5-Step Approach with Every Client

Over the years, we have determined that by following our 5-step plan, we can ensure a smooth process and a successful outcome for every project we take on.

Notice that the first step is always a discussion to determine if we are the right fit for a potential client’s needs. Do our capabilities match the requirements that the client presents to us?

  1. Initial Consultation: We must feel that we can provide either the facilities, the equipment, the process or the personnel that the client requires. Thus, there must be a mutual agreement that we are a good fit and will be able to work together as partners to help the client succeed.
  2. Research & Development: Testing, trial and error product development, new product creation, and improving existing products are all expensive procedures for any company. However, they often lead to innovations and new products that increase profits in the long-term. Using our facility to ensure product success is a major cost-savings for our clients upfront.
  3. Lab Testing/Sample: Before everyone approves the final product, it is always better to evaluate a sample and have it in hand. That allows us to discover any flaws in a design or process before we get too far along in the production cycle. We can produce a sample at any stage that we deem necessary to prevent expensive issues later on.
  4. Pilot Run: Our commitment to a perfect end result begins with a pilot run. Only by testing all systems, equipment and materials through a complete cycle will you discover some small issue that could present a major expense if left until the final production phase.
  5. Production: Finally, this step is the most anticipated, yet predictable phase. We already know that the final product will be perfect, since we have tested along the way and done a pilot run. At this point, everything is in place to ensure success for our clients.

Why Should We Choose CTI for our Contracting Needs?

If your company needs a contractor for the services that we offer and wants an experienced team that can take on the responsibility for superior execution of your plans, you can rely on the experts at CTI. You can see from our dedication to customer service and the steps that we take to offer superior equipment, personnel and a well-run facility, that we truly want to work as a partner with your team. We all have the same goal…to produce a product or component that would cost you much more to manufacture at your own facility.

Our technical support is superior, offering reliable solutions to our clients’ process-engineering issues.

Moreover, it is imperative that your products meet the criteria of the appropriate industry standards boards. Our accreditations include the ASME-American Society of Mechanical Engineers, ASTM-American Society for Testing and Materials and SAE-Society of Automotive Engineers.

Innovative technology and creative solutions are our standard. Our clients expect nothing but the best when they partner with Conversion Technologies, Inc. We look forward to discussing your next project with you. Feel free to call us at 419-924-5566 or complete this form and we’ll be in touch.