How to Choose the Most Suitable Die Cutting Manufacturing Process?
Die Cutting Manufacturing Process

How to Choose the Most Suitable Die Cutting Manufacturing Process?

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The die cutting manufacturing process is a fast and easy way to efficiently shape a range of different materials. Since 1955 Frank Lowe has offered a range of custom fabrication solutions, including:  

Our die cutting process allows us to quickly and precisely shape materials with exceptional accuracy. However, not all die cutting processes are created equally. Let's take a closer look at the four most popular die cutting processes and the factors that determine which fabrication solution is best for your application.

Flat Bed Die Cutting Manufacturing Process

As the simplest type of die cutting, flat bed die cutting may be more suitable for low volume or general cutting. Flat bed die cutting is also an extremely flexible and versatile solution that can be utilized with almost any material.

With flat bed die cutting, a machine systematically raises and lowers the die onto the material being cut. The flat bed die cutting manufacturing process is ideal for creating kiss-cut components or components with an adhesive backing supplied on a pad or roll. This type of die cutting allows for hole removal as well as web (scrap) removal from parts, which can save time and money. Flat bed die cutting also promotes faster changeover times.  

Rotary Die Cutting Manufacturing Process

The rotary die cutting manufacturing process is a fast method of fabrication and is exceptionally cost effective for higher-volume orders. With this method, the machine is fed rolls of material that is sent through the rolling die. The die then cuts the specified shape from the elastomer, while the waste is disposed into a catcher.

Rotary die cutting allows for jobs to be quickly repeated while minimizing waste. In addition, the rotary die cutting method is excellent for producing kiss cut components or parts.

Waterjet Cutting Manufacturing Process

The waterjet die cutting manufacturing process may be preferred whenever the die cut component or industrial gaskets have changing specifications. Instead of using a traditional die, the shape and dimensions of the desired component is input into a computer that is connected to the waterjet die cutting machine. Then the computer controls the hydro-jet cutter and directs a high-pressure stream of water through the material to create the desired part.

This method of die cutting allows for the production of materials of varying thickness and products to be altered on the fly — due to the fact dies do not need to be constructed. Waterjet die cutting can be less expensive for individual cuts, but can be more expensive for large production runs.

Laser Cutting Manufacturing Process

Similar to waterjet die cutting, the shapes of the desired component is input into a computer that is connected to the laser die cutting machine. Based on the computer's commands, the high-powered laser cuts exceptionally precise lines to create the desired component.

How to Choose the Best Die Cutting Manufacturing Process?

The hardness of the elastomer has the most significant impact on the type of die cutting manufacturing process. For harder elastomers, flat bed die cutting may be the best solution because it's able to exert significant amounts of force on the substrate. For softer materials, laser cutting and water jet may be more suitable.

However, the best way to choose the die cutting manufacturing process is with the assistance of the experienced professionals at Frank Lowe. Since 1955, Frank Lowe has delivered precise die cuts to help manufacturers improve processes and create better products. In every case,

Because there are hardly ever any one-size-fits-all solutions, we will carefully listen to the needs and requirements of your application. Then we'll guide you to the best die cutting manufacturing process.

Our specialists will also assist with materials selection — explaining the pros and cons of each type of potential elastomer. We'll match your application needs and requirements with the most ideal elastomer with budget considerations in mind.

Contact Frank Lowe for the Best Die Cutting Manufacturing Process

At Frank Lowe, we pride ourselves in going above and beyond to provide solutions that make a difference. We'll help move your project from conception through completion — offering a full complement of services along each step of the way.

We provide comprehensive design assistance, prototyping, and testing to make sure you have the right component for your application or product. With more than 60 years of experience, trust Frank Lowe to guide you to and through the die cutting manufacturing process.

About the Author Randy Cohen

Since 2002, Randy Cohen has served as the Senior Vice President of Frank Lowe — leading Sales and Marketing as well as a variety of Administrative operations. Randy has 25 years of experience with a background in sales & marketing, production and business management, serving both government agencies and private industry. He holds a B.A from Syracuse University and a Masters and Professional Diploma from Fordham University. Randy uses his unique set of experiences to help businesses and entities across all sectors explore, pursue, and create better solutions.

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