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Die Cutting Manufacturers and Companies

IQS Directory provides a detailed list of die cutting companies and suppliers. Find die cutting companies that can design, engineer, and provide die cutting services to your specifications. Peruse our website to review and discover top die cutting companies with roll over ads and complete product descriptions. Connect with the die cutting companies through our hassle-free and efficient request for quote form. You are provided company profiles, website links, locations, phone numbers, product videos, and product information. Read reviews and stay informed with product news articles. Whether you are looking for metal die cutters, large format die cutting services, and custom die cutting services of every type, IQS is the premier source for you.

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We know that high tech products require die cut parts that are created with precision and care. We have the highest quality standards in the die cutting industry because we know that with die cutting accuracy is so important. After we cut the prototype for your product and after receiving your approval we pledge that your orders will be shipped within ten business days or less. We know timelines matters this is why we strive to meet every deadline, every time. Get in touch with us today!
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When it comes to die cutting, we are the experts! We are a Grand Rapids, Michigan based company but we offer our services to all across the United States. It is our goal to bring exceptional die cutting services to all of our clients while also providing customer service that will keep you coming back to fulfill all of your die cutting needs. Our staff has the experience you can count on to assist you in your projects. Visit our website for more information or email us today!
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Gardico has been providing superior products and workmanship to industrial customers since 1977. Our die cutting capabilities satisfy needs for standard and custom gaskets, pads, insulators and decorative pieces in quantities from 5 or 10 to tens of thousands. We work with stock or customer provided materials: rubber, foam, vegetable fiber, cloth, cork, felt, gasket sheet, thin plastics and foils.
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Heubach has custom commercial die cutting capability to produce thousand of parts a day. Our steel rule die conversion process enables us to attain accuracy and efficient means of mass producing cut parts. We have high speed die cutting capability to produce fold lines, scores, perforated cuts and partial cuts. We specialize in all flexible items including HDPE, LDPE and non-woven laminates.
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We are your die cutting experts! Since we got our start over forty four ago we have been manufacturing top of the line die cut products that will provide a lasting value! Our products serve in industries such as aerospace, automotive and small engine, building and construction, food processing and a host of others. For more information about what we may be able to do for you get in touch with our customer service staff today!
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Die cutting and fabricating of non-metallic gaskets from a variety of materials: Neoprene, Buna-N, EPDM, Viton, Silicone, Natural Rubber and much more! From your most common washer type gaskets to your most intricate detailed gasket designs, we cut to your specs with the highest quality in mind. Fast prototypes, short or long runs - we welcome all requests!
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REDCO offers complete die cutting services to produce custom die cut gaskets and other custom die cuts that perfectly match our customers' specifications. All of our steel rule dies are laser cut to guarantee quality and accuracy of the finished product. We have over 65 years of experience in die cutting non-metallic and metal parts. We strive to provide the best possible prices, the best-quality products and on-time deliveries to a wide range of industries.
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National Rubber Corporation is a nationwide leader of die cutting services for a wide variety of industries and applications. We provide die cut product quantities from prototypes and short runs to large production runs. At National Rubber, we take pride in our ability to produce accurate die cut parts that are guaranteed to meet customer specifications and perform perfectly within the intended application.
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Industry Information

Die Cutting

Die cutting is the manufacturing process of stamping or cutting two dimensional parts out of flat sheets of material. This process, often used in conjunction with laminating services, is a crucial finishing service for a wide spectrum of parts, including rubber and foam gaskets, circuit boards, ID cards, stickers and a wide range of other adhesive-backed products.

Die cutting machines, which manufacture die cutting products, come in a variety of configurations, each specialized for creating different types of die cut shapes. Rotary die cutting is a continuous process that pushes material sheets through rolling calendar dies, while steel rule dies cut single or multiple sheets in batches. Laser die cutting, although it requires no die tooling and produces much less waste material, can be time consuming and costly for long runs; ultrasonic die cutting is a relatively new technology that uses ultrasonic vibrations to cut and heat seal edges simultaneously. Die cut foam is used extensively in medical, hydraulic, electronic and consumer industries as die cut gaskets, vibration absorbers, bandages and adhesives, while plastic die cutting produces a wide range of display items such as die cut handle bags and stickers. Rubber die cutting can also be used to make gaskets. Die cutters can be used to create all kinds of shapes out of all kinds of materials.

Rotary, steel rule, crush and kiss cutting are performed on flat sheets of material by a cookie cutter-like cutting tool called a die. Steel rule die cutting, the simplest and most common type of die cutting, uses sharpened, thin "steel rule" blade dies, which are embedded in rubber and mounted on a solid wood block. The rubber surrounding the steel rule's cutting edge serves to eject punched out pieces, and the sheets of foam, plastic or rubber are rapidly crushed between the die and a rubber pad with several tons of force. In rotary die cutting, sheets of material are crush cut between the angled blades on a cylindrical die and an anvil. Typically, the material is cut in continuous roll form, though sheets of metal can be fed through the rotary die. Rotary steel rule drum is a combination of rotary and steel rule die cutting, which is used to cut large parts such as boxes or garments with a high degree of accuracy. In ultrasonic die cutting services, a metal horn vibrates in a manner similar to that of an audio speaker, although ultrasonic waves are below the level of human hearing; the resulting vibrations generate heat and pressure that will seal thermoplastic materials. Laser die cutting machines, which are operated by CNC, are driven by a 3-axis table. Laser die cut machines come in two types: flat cutters, which cut flat sheets of material, and rotary cutters, which cut material from a web.

Steel rule dies are made for a number of applications. Conventional dies can attain the highest accuracies and the most intricate of forms as well as fold lines, scores and perforated or partial cuts. These dies are typically used to cut corrugated boxes, folding cartons, gaskets, plastics, fabric, rubber, foam and composites. The blades are held in place by high density plywood; the thickness of the blade is usually between .028" and .056". Heavy duty steel rule dies, such as clicker dies and bolt dies, have thicker blades (.056"-.112") to cut through thicker, tougher materials such as plastics, Kevlar, fabric, rubber, leather and composites to make a range of gaskets, vibration absorbers and plastic parts. Both rotary and steel rule die cutting can perform either kiss cutting or crush cutting. Crush cutting creates a cut all the way through the material sheet, making a clean, complete hole; foam pads, adhesive bandages, gaskets and rubber parts are usually crush cut. Kiss cutting, which is used only on adhesive-backed materials, cuts through the top layer of the material without cutting through the backing. This is used to create sheets of stickers, foam adhesives, bumpers and many other products that can be peeled off a backing sheet.

Rotary dies are typically used in the corrugated box industry, but they are also commonly utilized for plastics, foam, rubber and textiles. In rotary die cutting, parts are consistently within a tolerance as tight as .02", slightly higher than typical steel rule die cutting, which must be carefully aligned by hand and is more error prone. Laser die cutting can cut intricate, precision tolerance shapes and is very useful for cutting materials that are impossible for conventional steel rule dies to cut, such as steel thicker than .5". Laser die cutting can also be used to cut ABS, acrylics, aluminum, brass, composites, copper and cured fiberglass. Because laser die cutting uses no dies, it requires none of the costly initial tooling that all other types of die cutting requires; this cuts down on cost, while the laser die cutting process cuts down on wasted material due to its high tolerance capabilities. These properties make laser die cutting ideal for prototyping and short runs, but laser die cutting cannot cut parts at the speed and volume rotary and steel rule die cutters can, and most typical long run projects are still performed more time and cost efficiently by traditional dies. Ultrasonic die cutting is ideal for cutting thermoplastic materials that tend to easily fray. However, this type of die cutting is limited in that only relatively thin materials can be cut, and parts have a small maximum width. Each die cutting method can be a great asset to all kinds of industrial and commercial operations.


Die Cutting
Die Cut Shapes
Images Provided by Thrust Industries

Laser Die Cutting
Image Provided by Design Converting, Inc.




What is Die Cutting?

Die cutting is a high-speed fabrication method that utilizes a die to cut sheet metals and other low-strength materials, including fiberboards, rubber, plastics, adhesive tapes, and foam.

The die cutting method has its roots in the shoe industry, where it was used to cut leather into different shapes by exposing it to press installed with a cutting die, which carved pre-determined shapes based on the die. The process in the modern time includes sophisticated robots and high pressure presses that can shear webs even in a thick hard metal.

However, sometimes the term die cutting stems confusion as it is quite ambiguous and its meaning differs in different fields. For instance, stamping is a type of die cutting, where sheet metals are stamped to give specific shape.

In the fabricating industry, die cutting method draws its name from the die used for webbing shapes. Other than cutting a material, a die can perform other functions as well, such as, forming, which involves compression and other stressing method for producing desired shapes. The function of a die will perform depending on the way a die is tooled; dies can be divided two sections, one for cutting and other for forming. The die's cutting section can be made from an array of hard and wear resistant materials, like hardened steel and carbide.

Die Cutting Process

Die cutting is a cold operation that does not need heat to change the physical properties of a material. Instead, brute force is employed to cut pieces of required shape and size with the help of a press. The material that has to be stamped is positioned on the press with the help of auxiliary tools that lets the die pass through it. Then the press puts the material under high perpendicular force in flatbed press, where as in rotary die cutting, the force is put at different angles, which cuts parts by a continuous rotating action. If the material is a hard metal, the force acted on the material results into a shock, which can damage both the die and press. The freshly cut part has a shiny cut band or shear, which is known as the break line. However, heat is not introduced into the operation, the cut parts leave the die at high temperature because of the heat created by friction.

In different fields, die cutting is known by the material it is fabricating, for example, foam fabricating cutting die, rubber die cutting, plastic fabrication cutting die. Based on the industry, different types of hydraulic presses are used.

  • Swing arm cutting press, also known as clicking press, which draws its name from the cutting action.
  • Travelling head cutting press has motorized cutting head that travels on a frame
  • Automatic travelling head cutting press
  • Fixed beam cutting press
  • Receding head cutting press
  • Optical registration die cutting press

Die cutting is used extensively to fabricate a range of materials in different industries.

Factors to Consider While Purchasing a Suitable Die Cutting Machine

Die cutting is an important process of cutting materials in a desired shape by a manual or electrical processed die cutter. Besides shaping paper and plastic, fabric and rubber products, it is also used to cut metals in well-defined shapes and patterns. Used with stamping or embossing machine, it gives a perfect finish to stamped paper, plastic or metal products.

People who need large number of die-cut products on a daily basis should invest money in purchasing a suitable die cutter along with the dies. However, buying die cutter that fulfills your requirements and provides you maximum profit requires that you consider some of these essential factors that will go a long way to enable you make the right choice among a plethora of options.

  1. Assess your requirements and go for the suitable type
  2. Although the basic functionality of all types of die cutting machines is same, there is a great difference in the usability and cost of the machine. Based on your paper, plastic, rubber, aluminum, or other metal cutting requirements you would have to select die cutter that is specialized for your cutting requirements. You can select from manual die cutters to computerized die cutters that requires

  3. Purchase suitable dies according to your requirements
  4. A die cutting machine is useless without suitable dies, which are fabricated precisely by professionals. Dies come in various shapes and sizes and it is important to check the compatibility of dies with the machine. Manual die cutting machines may work with many types of dies from other companies while computerized die cutters are limited in this aspect due to the specific software programs. Buyers should check out various options of dies to make the right decisions.

  5. Installation and portability of the machine
  6. Setting up a die cutting machine may be time consuming. Hence, buyers must check as how much time it takes to install the machine and also check the portability of the machine. A small sized and easy to be installed machine must get to be on the high priority.

  7. Storage of the die cutting machine
  8. As a buyer you should check the space available for storage of your die cutting machine. This will give you a fair idea about the size of the required machine. Besides considering the usability of the machine, you must look at how much space the machine will take up and how difficult it will be to store properly without risking damage to the machine.

  9. Cost of the machine
  10. Die cutting machines according to their features are available in a specific price range. Considering your die cutting requirements and long term budget you should invest in buying expensive or less expensive models from the reputed supplier. You should compare prices and do proper research before buying the die cutting machine and get the maximum value for money. You can get the best price quote from the leading supplier and thus purchase suitable die cutting machine at a reasonable price.

Die Cutting-Operations and Presses Involved

Die cutting is used extensively as a fabricating method in the manufacturing industry. Different types of materials, ranging from metal sheets to cardboard, to rubber and plastics, are cut into desired shapes with the help of die cutting presses. By die cutting, different products can be fabricated at high-speed and with precision. The efficiency of die cutting units has made it the most viable manufacturing process that does not involve heat.

In die cutting, two things matter, first a die and second the press that provides force to form shapes. Since, cutting dies are used in a number of industries there are a variety of die cutting operations.

  • In blanking operations, a piece of flat or processed profile is cut entirely from a flat material with a single movement of press. The die compresses the material uniformly at all contact points for fabricating a flat product. Blanking is considered a dual-purpose operation and performed at a larger scale.
  • In trimming operations, the perimeter of a pre-processed or flat sheet material is trimmed away for providing the required profile. The material trimmed away is sent for recycling.
  • In notching operations, progressive dies notch the out edges of a material sheet progressively to give a desired shaped.
  • Bending involves giving shape to a material by exerting pressure from a die. For instance, in a typical operation, the forming part of a die exerts pressure on a material and bends the material at a 90-degree angle.
  • Die cutting also involves piercing, also known as perforation; this operation produces specific shapes in a flat material, the hole based on the die design can be a circle, square, or a custom design. The operation seems similar to blanking, however, the difference is that in blanking, slugs are used for further press working, whereas in piercing, the pierced part is sent to scrap.
  • In lancing operations, a part of the material is slit or sliced; however, at one point it remains attached to the strip. This type of operation is done on a progressive dies.
  • Shearing is the simplest operation that involves slicing the material strip in a straight line. By this operation, blanks are produced, however, in the rectangular and square shapes.

Now, moving to presses employed in die cutting. Typically, two types of presses are used, either flatbed or rotary presses.

In flat-bed presses, in the most common design, the force is exerted perpendicularly to material that needs to be fabricated. The presses usually are driven hydraulically. However, mechanical models may also be available.

In rotary die cutting, a cylindrical die is used, which is fitted on a rotary press. The press works continuously and cut pieces as it rotates, making the operation efficient and fast. Both presses have their own set of advantages and disadvantages, as flat bed press is not fast as that of rotator presses. However, the tooling of flat bed is inexpensive in comparison to rotary press.

Fulfill Your Industrial Die Cutting Requirements with Specialized Machines

Die cutting is the industrial process of cutting flat sheet of materials like rubber, fiber, paper, or metals in the desired pattern to produce these products in bulk. Starting as a process of cutting leather for shoe industry, die cutting became more sophisticated to be used in producing a wide range of products like circuit boards, ID cards, credit cards, labels and stickers, adhesive tapes and stamps, and metallic products. Various die cutters are used that are specialized to cut different products like furniture, plastic, paper or metals in specific designs and patterns.

Several traditional forms of die cutters are widely used across industries, which includes rotary, press, and flatbed die cutting machines. Many new forms of die cutting machines are also increasingly getting popular such as water jet die cutting, ultrasonic die cutting, and laser die cutting.

Die cutters use specially shaped blades for sharp and precise cutting. The material to be shaped is placed on a flat surface with a supportive backing and the die is pressed against the material to cut it. Depending on the type of material to be cut, the machine may either cut and form a piece of material or slice multiple pieces of materials stacked one over the other.

Whether you have to cut machine parts and form intricate designs or you have to cut a sheet of paper you should select a suitable die cutter that would fulfill your cutting and shaping requirements. It can be quite time and cost saving to procure services from die cutting companies if you require die cut components on a less frequent basis.

You can find many computerized die cutters and portable die cutters that may be either manual die cutters or electronic die cutters. Besides these you may procure industrial die cutters that make stainless steel dies with a hydraulic press. What make die cutters so popular are their precise cutting as well as versatility. Die cutters have evolved from simple manual cutters to computerized cutters using the CAD software and the latest technology.

Whether you require a Rubber Die Cutting machine or a flatbed cutting machine for stamps and stickers you can either purchase the machine from reputed supplier or get personalized die cutting service from the company. The die cutting action in press die cutters is controlled by manual, hydraulic, pressurized, or electric sources depending on the type of the machine.

When it comes to cutting materials involving different kind of shapes and get high design flexibility then selecting flatbed die cutters is the best bet. This machine uses steel rule dyes with a hydraulic press that can make precise kiss-cuts and die-cuts into sheets and laminates.

Die cutting is one of the most important processes for the manufacturing industry as most of the flat shaped objects are produced through it. Products like keys, paper products, and flat plastic pieces as well as metallic components, corrugated envelopes, cartons, gaskets, fabric, and rubber products are manufactured through die cutting. Selecting a suitable die cutting machine depends on many factors like the material to be cut, the structure or design to be formed, the volume of cutting requirements, the speed of the machine as well as the method of cutting that will suit the needs.




Die Cutting Types

  • Die cut foam is used in packaging, inserts, insulation and cushioning to protect objects from breakage, as it provides a certain degree of shock and vibration absorption.
  • Die cut gaskets are rings, often made of rubber, that function as sealants and are commonly used in EMI shielding.
  • Die cut machines are tools that use dies to cut material into specific shapes.
  • Die cut shapes are forms cut out with dies.
  • Die cutters are equipment that use sharpened steel blades that cut shapes from various materials.
  • Die cut tape is used to adhere objects to one another, to hold objects in place and to prevent the scratching of components.
  • Kiss cutting is the process of creating cuts in thin products that have adhesive backings.
  • Laminating services can be either the joining of two or more materials together using heat, adhesives or pressure, or the application of a clear plastic film to the exterior of flat objects.
  • Laser die cutting applies a fully-focused laser beam instead of a die in order to convert material into custom shapes and sizes.
  • Plastic die cutting produces numerous objects ranging from plastic tape and films to plastic bags and is useful in applications requiring heat-sealing and fluid resistance.
  • Rotary die cutting is a method of forcing material between the sharpened blades on a cylindrical die and a hard cylindrical anvil on a rotary press in order to cut and score materials with tolerances as tight at .02".
  • Rubber die cutting is the use of a die cutter in the production of rubber grommets, bumpers, bushings and other rubber products.
  • Steel rule dies are flatbed dies containing sharp blades in the die board situated in a particular line in accordance with the required part design.

Die Cutting Terms

Air Holes - Holes in die cutters that aid in the prevention of deformations in die cut materials by allowing the release of air from the die cavities.
 
Anvil - The surface upon which the materials to be die cut rest.
 
Automated Feed Systems - Components of certain die cutting machines that provide the continuous, automatic supply of material to the die cut machine.
 
Capacity - The widest part that can be cut on the equipment.
 
Chisel Punches - Blades located either on the die or another part of the press that produce a separation in die cut materials.
 
Composite - A material obtained by layering and bonding with resin sheets of woven material to obtain specific characteristics and properties. The materials are not completely blended and so remain physically identifiable.
 
Deflection - Unwanted deviation from parallelism in the top die plate.
 
Die Blade - A steel blade attached to the die that performs the cutting procedure by penetrating through the die cut substance.
 
Dieboard - Steel rule die component, often consisting of plywood, in which the die blades are inserted.

Kevlar - DuPont's trade name for aramid fibers that are strong, tough and stiff, have a high melting point and are used in composite construction. Kevlar is lighter, stiffer and more costly than glass fiber.

Kiss Cut - A die cut that penetrates the upper layer(s) of the die cut material instead of penetrating through the material.
 
Knifing - The process of fitting the steel die blades into the die board of a steel rule die.
 
Nicks - Indentations in a die rule that stop the cutting.
 
Punch - The die component that actually forms, or punches, a shape from the die cutting material.
 
Through Cutting - Die cutting in which the die cut material is penetrated all the way.
 
Ultrasonic - A frequency usually higher than 20 kHz, which is too high to be heard by the human ear.
 
Web - Continuous roll form.





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