At Techprint, our die-cut parts are engineered to streamline production, improve consistency, and support high-volume manufacturing. Drawing on extensive die-cutting expertise across electronics, packaging, and other industrial applications, Techprint helps customers design components that meet tight tolerances while optimizing manufacturability and cost. Here, we’ll discuss our die-cutting process, equipment, and materials, as well as the key considerations we address when designing die-cut parts for reliable performance and efficient production.
Die Cutting Process at Techprint
Our die-cutting process is a fast, repeatable, and automated manufacturing method. A standard or custom-shaped die cuts layers of materials into precise shapes for a wide range of applications. The metal die has sharp edges that cut through a single layer of material or a stack of multiple layers. For custom components, we can design a die that matches the unique shape and dimensions of the desired part.
Techprint’s Die Cutting Equipment
- Flatbed Die Cutters. Thomson and Preco presses utilizing Steel Rule dies and Chemically etched flexible dies.
- Rotary Die Cutters. Flexographic presses utilizing Solid Rotary Dies and Chemically etched flexible dies.
- Laser Cutting. Zund, Eurolaser, Coherent CNC machines utilizing optical registration systems.
- Knife/Blade Cutting. Zund CNC machines utilizing optical registration systems.
- Hydraulic Presses. Utilizing male/female matched die sets.
Materials We Work With
Some of the materials we commonly use to create standard or custom die-cut parts include:
- Plastic Film: Polycarbonate (Lexan, PC), Polyester (Mylar, PET)
- Adhesives: Pressure-sensitive adhesive (3M), Pre-mask films, gaskets.
- Thermal Management: Graphite, gap pads, heat sink materials.
- EMI/RFI Shielding: Conductive foams, copper foils, and fabrics.
- Medical Grade Substrates: Bio-compatible adhesives, foam, hydrogel, medical tapes.
- Specialty Polymers: Polyimide (Kapton), PTFE, elastomeric rubber.
Common Applications of Our Die Cutting Services
We apply our die cutting to the production of:
- Graphic overlays
- Printed labels (compliance, bar code, identification, medical)
- Printed electronics
- Gaskets (Rubber, Foam, films, Adhesives)
- Insulators (Polyimide, Kapton, Mica, Ceramic, Adhesives)
- EMI Shielding (Copper, Aluminum foil)
- Medical tapes and patches
Our die-cutting capabilities can produce a wide variety of shapes and sizes in various materials to exacting standards. Complexity is not a problem, whether you need prototypes or high-volume production.
How We Support Your Die-Cutting Project
Thorough planning and preparation can make creating thousands or even hundreds of thousands of die-cut parts simple. Here are the key factors we consider throughout your die-cutting project.
1. Material Selection: Matching Material to Application
We help you select the right material based on environmental conditions like moisture or vibration, and what the die-cut part will adhere to, as some materials are incompatible. As a converting service provider, Techprint can help you compare the properties of various material options and source these materials through vetted suppliers. We can also consider factors such as cost, or evaluate whether newly developed materials on the market can better serve your needs.
2. Design for Manufacturability
Techprint can also improve your product design and optimize it for manufacturability. Designing for manufacturability (DFM) considers whether there are design details that are susceptible to failure or may introduce additional costs. For example, sharp corners are more cost-effective to produce than rounded corners. We can also help refine your casting design with manufacturing best practices, like ensuring all internal cutouts have a margin of at least 3 mm and calculating practical tolerances for multi-layered components.
3. Setting Die-Cutting Tolerances
While tight tolerances can guarantee more precise components, several variables can affect the practicality of striving for precise die-cut tolerances:
- Flexible materials can react to die-cutting less predictably than rigid ones, as some materials may compress or stretch.
- Thicker or larger parts require larger tolerances.
- Tighter tolerances require more specialized tools and longer production times, affecting project timelines and budgets.
- Environmental conditions, including moisture and temperature, can cause dimensional changes.
We assess these factors and propose reasonable tolerances for your project’s unique needs.
4. Part Presentation: Considering Your Workflow
We consider how you want parts to be delivered. Depending on your workflow, you can request die-cut parts on rolls, kiss-cut, with pull tabs, or with removed slugs. Each one offers different advantages. For example, parts on rolls can be more efficient to process, while parts with pull tabs make it easier to remove liners and apply them to substrates.
5. Prototyping: Identifying Design Flaws Early
Before mass production, we test and prototype until your product design is ready. We can use small prototype runs to evaluate the final appearance, address flaws, and test product performance. Once you finalize the casting design, mass production can begin.
6. Optimizing Scalability
Our converting and die-cutting services can streamline the production of die-cut goods through automated processes. We implement best practices that reduce time spent, waste, and errors:
- Choosing high-quality liners that are easy to remove and don’t tear under pressure.
- Using visual or inline inspection processes that can catch misaligned or misoriented parts early on, minimizing waste and delays.
Die-Cutting Services From Techprint
Die-cutting is a fast, efficient, and precise manufacturing method that produces precise electronic, packaging, industrial, and medical device die-cut parts. At Techprint, we design and produce high-quality die-cut components that can meet the exact specifications and requirements of your manufacturing project.
Contact us today to learn more about our die-cutting capabilities, or request information to start your project.