Posted by mevjen on | Comments Off on What You Need to Know About CNC Fabrication for Non-Metallic Materials
For many manufacturers and OEMs, CNC fabrication is the bridge between concept and full-scale production.
During early production or when designs continue to evolve, CNC fabrication can be an effective manufacturing method for components and gaskets made from plastics, foam, rubber and composite materials.
Using computer-controlled routing and knife-cutting equipment, CNC systems produce accurate, repeatable parts directly from CAD files. Because dedicated hard tooling is not required, manufacturers can move quickly from design to production while allowing flexibility for engineering changes.
This makes CNC fabrication particularly well suited for rapid prototypes and applications where precision and adaptability are critical.
CNC techniques for non-metallic materials
CNC fabrication is especially effective for non-metallic materials because cutting parameters can be adjusted based on the characteristics of the material being processed.
Cutting speed, feed rate, tooling and tool path all influence dimensional stability, edge quality and finished part performance. Selecting the appropriate CNC process helps minimize issues such as heat buildup, tearing, compression or material displacement.
CNC routing
CNC routing is commonly used for rigid materials such as plastics and composites.
Because many plastics are sensitive to heat, routing parameters must be carefully controlled to prevent melting, edge deformation or surface damage. Properly balancing feed rate, spindle speed and tooling geometry allows chips to carry heat away from the cutting area rather than allowing excessive friction to build.
The result is improved edge quality, dimensional accuracy and surface finish. CNC routing also provides the flexibility to manufacture larger and thicker plastic components without the cost and lead time associated with complex hard tooling.
Common materials include plastics and composites.
CNC flash cutting
CNC knife or flash cutting is commonly used for softer, flexible materials such as foam, rubber, silicone and layered adhesive constructions.
Using oscillating or drag blades, this method slices cleanly through substrates while minimizing compression and material displacement that can affect part fit.
For laminated materials, such as foam combined with pressure-sensitive adhesive, CNC cutting can help maintain layer alignment and produce consistent dimensions throughout the finished component.
Common materials include foam, rubber and silicone, often laminated with pressure sensitive adhesive, and other flexible materials.
Benefits of CNC Fabrication
Precision manufacturing
CNC equipment provides precise control over cutting paths and dimensions, making it well suited for complex geometries and applications requiring close tolerances.
Depending on the material, thickness and part design, CNC fabrication can achieve very tight tolerances while maintaining repeatable production from part to part.
Consistency & repeatability
CNC fabrication produces identical parts with high repeatability, reducing waste and rework. It places less stress on the material, with vacuum suction to hold it in place during the cutting process. Reliable production of foam, plastic and composite components at the front end supports higher product quality, which means less maintenance and better performance for the end user.
Design flexibility
One of the greatest CNC fabrication benefits is the ability to accommodate design changes without creating new hard tooling. With CNC fabrication, you can easily accommodate prototypes, design revisions and short production runs without disrupting your development schedule. Updates can be implemented through simple CAD changes, eliminating the added lead time and expense of new hard tooling.
Reduced material waste
Advanced nesting techniques in CNC fabrication maximize the number of usable parts from each sheet of material, improving material utilization and lowering overall production costs.
Scalable production
CNC fabrication can also serve as a bridge while permanent tooling is being developed, modified or validated.
Manufacturers can continue producing parts while tooling progresses, helping keep development and production schedules moving forward.
Once volumes increase or the design is finalized, production can transition to another manufacturing process when appropriate.
Quality control
Using a CNC process can improve quality control in several practical ways, especially for plastics, foam, rubber, and composites.
Repeatability: Parts are produced from the same CAD program and cutting path, helping maintain consistent dimensions from part to part.
Dimensional accuracy: CNC equipment can hold close tolerances when the material, tooling, and process are properly controlled.
Reduced operator variation: Once the program and setup are validated, the process is less dependent on manual cutting or operator technique.
Controlled cutting parameters: Feed rate, spindle speed, blade speed, and tool path can be standardized to reduce melting, tearing, compression, or edge distortion.
Consistent material positioning: Vacuum hold-down systems help keep sheet materials stable during cutting, reducing movement and dimensional variation.
Cleaner edges and finishes: Proper CNC settings can reduce burrs, chip welding, rough edges, and other defects that may lead to scrap or rework.
Digital traceability: CAD files and machine programs create a repeatable manufacturing reference, making revisions and process control easier.
First-piece and in-process inspection: CNC parts can be checked against the CAD dimensions before a production run continues, helping catch issues early.
When to choose CNC fabrication
CNC fabrication excels in situations where precision, flexibility and material performance are prioritized over the benefits of high-volume tooling.
CNC fabrication is often the right choice when:
Parts are manufactured from plastics, foam, rubber or composite materials that require controlled cutting methods
Product designs are still evolving and engineering revisions are expected
Prototypes or pilot runs are needed before investing in permanent tooling
Tight tolerances or complex geometries are required for proper fit and assembly
Laminated or multi-layer materials must remain aligned during fabrication
Production must continue while hard tooling is being developed or modified
Material utilization and scrap reduction are important cost considerations
Partner with a precision expert
Successful CNC fabrication involves more than simply cutting a part from a CAD file. Material selection, cutting parameters, nesting and production strategy can all affect part quality and overall manufacturing cost.
Working with an experienced fabrication partner early in the development process can help improve manufacturability, material utilization and the transition from prototype to production.
Climatech supports OEMs with CNC routing and cutting capabilities with a wide range of non-metallic materials, backed by material selection, adhesive lamination, prototyping, engineering support and scalable production solutions.
FAQs about CNC fabrication for non-metallic materials
What is CNC fabrication for non-metallic materials?
CNC fabrication uses computer-controlled cutting methods to shape plastics, foam, rubber and composite materials with high precision. Parts are produced directly from CAD files, allowing accurate, repeatable fabrication without the need for hard tooling.
What materials can be fabricated using CNC cutting?
CNC fabrication is commonly used for polycarbonate, polyethylene plastics, composite materials, foam, rubber, silicone and laminated adhesive constructions. The cutting technique is selected based on material rigidity, thickness and performance requirements.
When is CNC fabrication preferred over die cutting or molding?
CNC fabrication is often preferred for rapid prototypes, short production runs, bridge production and applications where designs are still being refined. Because dedicated tooling is not required, engineering changes can be implemented quickly without producing new dies
How accurate is CNC fabrication?
CNC fabrication can achieve very tight tolerances, depending on the material, thickness, geometry and cutting process. This precision makes CNC manufacturing well suited for components requiring consistent fit and repeatable assembly.
Why is CNC fabrication well suited for plastics and foam?
Non-metallic materials are sensitive to heat, compression and tearing. CNC systems precisely control feed rate, cutting speed and tool paths to minimize material distortion, prevent melting and maintain dimensional stability.
What is the difference between CNC routing and CNC knife cutting?
CNC routing uses rotating cutting tools (router bits) and is typically used for rigid materials such as plastics and composites. CNC knife cutting uses oscillating or drag blades to cut flexible materials such as foam, rubber, silicone and adhesive laminates with minimal compression or material displacement.
Posted by mevjen on | Comments Off on What You Need to Know About High-Temperature Gasket Materials
In high-temperature industrial environments, gasket failure is often the earliest point of a failure in system performance.
As temperatures rise, materials expand, adhesives can soften, elastomers may harden and compression set can accelerate. A poorly selected gasket can lose elasticity, crack or no longer maintain sufficient sealing force, increasing the risk of leaks and premature failure.
Choosing the right high-temperature sealing material requires more than comparing maximum temperature ratings. Chemical exposure, compression, vibration, environmental conditions and duration of heat exposure all influence long-term gasket performance.
What is a high-heat gasket?
Metal and ceramic sealing materials can withstand extremely high temperatures, while elastomeric gasket materials generally operate within lower temperature ranges depending on the specific formulation.
In many industrial applications, however, elastomeric materials are preferred because they provide:
Effective sealing against dust, moisture and contaminants
However, once temperatures exceed 200°F, long-term performance can be impacted. Over repeated exposure cycles that are common in industrial environments, thermal aging can stiffen elastomers, weaken bonds and compromise seal integrity.
Another important factor is heat is rarely the only stressor to your high-heat elastomer gasket. These are often exposed to other harsh operating conditions including:
Oils and fuels
Harsh chemicals
Pressure fluctuations
Outdoor weathering
UV and ozone
Mechanical vibration
Key factors when selecting high-temperature sealing materials
Operating Temperature Range
Evaluate both continuous operating temperature and short-duration temperature spikes. A material may tolerate a high peak temperature but degrade more quickly under prolonged or repeated exposure.
Mechanical Performance
Heat changes material behavior. Evaluate whether the material retains their properties after prolonged exposure.
Compression set
Tensile strength
Elongation
Flexibility
Resistance to cracking
Compression Recovery
Chemical Compatibility
High temperatures can intensify chemical attack when exposed. Consider the material’s resilience to:
Petroleum-based oils
Fuels
Organic solvents
Steam
Acids
Environmental Exposure
Outdoor applications may also expose seals to UV, ozone, moisture, dust and freeze-thaw cycles. These factors should be evaluated along with temperature when selecting a gasket material.
Best High-Temperature Elastomer Sealing Materials
Below is a comparison of commonly used elastomeric gasket materials and how they perform under elevated heat.
Temperature ranges vary by formulation and manufacturer, so specifications should always be confirmed for the specific material being considered.
Butyl Rubber
Operating temperature: -60°F to 250°F
Material type: Copolymer of isobutylene and isoprene
Best for: Airtight sealing applications
Benefits:
Excellent resistance to thermal aging
Strong resistance to ozone and weather
Good chemical and abrasion resistance
Very low gas permeability
Limitations:
Not recommended for petroleum exposure
Limited upper temperature capability compared to silicone or fluoroelastomers
Nitrile (Buna-N)
Operating temperature: -40°F to 212°F
Best for: Oil and fuel contact applications
Benefits:
Excellent resistance to oils and gasoline
Good compression set resistance
Strong mechanical durability
Limitations:
Not flame resistant
Poor resistance to UV and ozone
Degrades with exposure to organic solvents like acetone or ethanol
Beyond Elastomers: Materials for Extremely High-Temp Applications
Prolonged exposure to elevated temperatures can significantly affect gasket performance. Depending on the elastomer and formulation, excessive heat can cause rubber gaskets to harden, shrink, soften, deform or lose their ability to maintain an effective seal. Flammability and maximum operating temperature also vary by material, making it critical to select a gasket designed for the specific thermal environment.
For extremely high-temperature applications — particularly those exceeding the practical limits of elastomeric materials — non-rubber gasket materials such as graphite or mica may be more appropriate.
These materials can withstand substantially higher temperatures but are generally less compressible than rubber or foam-based sealing materials. As a result, gasket selection should balance temperature resistance with the compression, conformability and sealing performance required by the application. When temperatures exceed the practical limits of elastomeric gaskets, non-rubber materials may be required to prevent rapid thermal degradation.
Common options include mica-based materials reinforced with stainless steel, aramid fiber materials with nitrile binders and metallic inserts, and vermiculite-based materials such as Thermiculite®. Certain Thermiculite® grades are designed for service approaching 1,000°C and offer strong oxidation resistance compared with graphite-based materials.
Other materials used in extreme-heat applications include high-temperature mica and other inorganic fiber-based sealing materials. These materials are designed for high-temperature gasketing and thermal insulation applications, while mica-based materials can provide reliable sealing performance in hot, dry environments.
Considerations
Because these materials are generally less compressible than rubber or foam-based gaskets, selection should consider not only temperature resistance, but also flange condition, pressure, chemical exposure, thermal cycling and the amount of conformability required for an effective seal.
Heat resistant gaskets start with design
At Climatech, high-performance sealing solutions begin with proper material selection and component design.
Our team works with OEMs to evaluate temperature, chemical exposure, compression, environmental conditions and manufacturability before a component moves into production. Climatech’s die-cut fabrication capabilities allow us to convert a wide range of foams, sponges, elastomers and adhesive-backed materials into precision high-heat gaskets and custom sealing components.
By combining material knowledge, engineering support and manufacturing capabilities, Climatech helps customers develop sealing solutions designed around the specific demands of their application.
If you’re evaluating high-temperature sealing materials for your next industrial application connect with our team.
FAQs: High-Temperature Sealing Materials
What is considered a high-temperature gasket?
In most industrial applications, elastomeric gaskets operating above 200°F (93°C) are considered high-temperature. However, the definition depends on continuous exposure, not just short spikes. A material’s long-term thermal stability matters more than its brief peak tolerance.
How does heat affect elastomer gaskets over time?
Sustained heat accelerates thermal aging. Over time, gaskets may lose elasticity, harden, crack or develop permanent compression set. As sealing force decreases, the risk of leakage increases — even if the gasket appears intact.
Which gasket material works best for both heat and oil exposure?
Fluoroelastomers are typically the strongest option when high heat and petroleum-based oils or fuels are both present. Nitrile also resists oil but has a lower temperature range. The right choice depends on the operating temperature and chemical exposure profile.
How does silicone compare to EPDM in high-temperature environments?
Silicone generally handles higher temperatures — often up to 400–500°F depending on formulation — and maintains flexibility across wide temperature swings. EPDM performs well up to around 275°F and offers excellent UV and weather resistance but is not suitable for petroleum exposure.
Why is compression set important in high-heat sealing applications?
Compression set measures a gasket’s ability to recover after being compressed. Elevated temperatures accelerate permanent deformation. If a gasket cannot recover properly, sealing pressure drops and leaks may develop — particularly in enclosures or flanged joints.
Posted by mevjen on | Comments Off on How Vibration Damping Materials Improve Industrial Equipment Performance
Vibration is a common challenge for OEMs and industrial equipment manufacturers. Mechanical energy traveling through machinery, components and surrounding structures can create unwanted movement, noise and wear that affect both equipment performance and the operating environment.
Unmanaged vibration can contribute to:
Increased stress and friction on critical components
Premature wear or failure of bearings, seals and fasteners
Increased maintenance requirements and unplanned downtime
Transfer of noise and vibration into floors, walls and adjacent equipment
Louder and less comfortable working environments
Increased risk of employee exposure to potentially hazardous noise levels
OSHA establishes an 8-hour permissible exposure limit of 90 dBA for occupational noise and an 85 dBA action level for general industry hearing conservation programs.
The right combination of vibration damping materials, isolation and structural design can help control these effects while improving equipment durability and performance.
Three Approaches to Industrial Vibration and Noise Control
Effective vibration control starts with understanding where vibration originates and how that energy travels through the equipment. Engineers generally use three strategies—often in combination:
Dampen: Damping materials such as elastomers, foams and viscoelastic polymers absorb vibrational energy and dissipate much of it as low-level heat, reducing resonance and vibration amplitude.
Isolate: Pads, mounts, bushings and other isolating components interrupt the transmission path between the vibration source and surrounding structures, reducing vibration transferred into frames, floors, housings and adjacent equipment.
Stiffen: Increasing structural rigidity can change a component’s natural frequency and move it away from problematic resonance ranges. Reinforced structures, engineered plastics and composites can help reduce unwanted movement and vibration response.
What Materials Are Used for Industrial Vibration Damping?
There is no single vibration damping material that is best for every application. The right choice depends on vibration frequency, loading, temperature, compression, environmental exposure and equipment design.
Material
Key Benefits
Common Uses
Sorbothane®
Proprietary viscoelastic polyurethane designed for shock absorption, vibration isolation and damping. According to the manufacturer, it can absorb nearly 95% of shock energy and reduce more than 50% of vibration energy in certain applications.
High-load or sensitive applications where controlling shock and transmitted vibration is critical
Polyurethane Foams
Provide vibration damping, impact absorption, cushioning and recovery after repeated compression. Available in different densities and cell structures.
Gaskets, pads, spacers, equipment enclosures and housings
PET / Polyester Fiber Mats
Lightweight, moisture-resistant acoustic material that helps absorb airborne frequencies.
Internal cavities, acoustic blankets and equipment enclosures
Closed-Cell Polyethylene Foam
Resists moisture while providing cushioning, thermal insulation and high-frequency noise control.
Marine, outdoor and moisture-exposed equipment
Silicone Foams & Sponges
Combine vibration control with resistance to elevated temperatures and environmental exposure while maintaining flexibility across a broad temperature range.
High-temperature equipment, gaskets, seals and cushioning components
Neoprene & EPDM
Neoprene provides vibration control and resistance to oils and abrasion. EPDM offers excellent resistance to weathering, ozone, moisture, UV and heat.
Gaskets, seals, pads, bushings, motor mounts and weatherstripping
Mass-Loaded Vinyl (MLV)
Combines flexible PVC with dense mineral elements such as barium sulfate to create a thin, flexible sound barrier that helps block airborne noise and reduce vibration transfer.
Equipment enclosures, housings and space-constrained noise-control applications
Material selection is only part of the solution. How the material is fabricated and incorporated into the equipment can be equally important.
Common Applications for Vibration Damping Materials
Sound-Deadening Pads
Sound-deadening pads made from viscoelastic materials, elastomers or engineered foams can be applied directly to equipment panels, housings and enclosures. Available with or without pressure-sensitive adhesive, they can be precision cut to reduce panel resonance, structure-borne vibration and radiated noise.
Gaskets and Seals
Die-cut elastomeric gaskets and seals can serve multiple functions within the same component. In addition to protecting against dust, moisture and contaminants, the right material can cushion mating surfaces, reduce vibration transfer and limit movement and friction between components.
Viscoelastic Damping Components
Viscoelastic materials applied to sheet metal, panels, housings and other structures help dissipate vibrational energy. This reduces structural vibration and the noise that can radiate from vibrating surfaces.
Pads, Spacers and Isolation Components
Custom die-cut foam and elastomeric components can be positioned between assemblies or beneath individual components to reduce direct vibration transfer. Thickness, density, compression and load requirements can be engineered around the specific application.
Choosing the Right Vibration Damping Material
Effective vibration control requires more than simply placing a soft material between two components. The material and component design must match the operating conditions of the application.
Important considerations include:
Vibration frequency and amplitude
Static and dynamic loading
Required compression and recovery
Operating temperature
Exposure to oils, chemicals, moisture or UV
Flammability requirements
Desired service life
Material thickness and available installation space
Adhesive and lamination requirements
Component geometry and manufacturing tolerances
Evaluating these factors early in the design process can help OEMs develop a more effective and durable vibration-control solution.
Engineered Solutions for Industrial Vibration Control
Vibration may be unavoidable in industrial equipment, but its impact can be controlled.
At Climatech, we work with OEMs and manufacturers to turn vibration, noise and sealing requirements into precision-engineered components. Through material selection, precision die cutting, fabrication and adhesive lamination, our team can manufacture custom gaskets, seals, vibration damping pads, cushioning components and other non-metallic solutions designed to support quieter operation, reduced mechanical wear and long-term equipment performance.
Need help with a vibration or noise-control application? Contact Climatech to discuss your requirements and explore a custom-engineered solution.
FAQs About Industrial Vibration Damping Materials
What are vibration damping materials?
Vibration damping materials absorb and dissipate vibrational energy to help reduce resonance, noise, vibration transfer and mechanical wear. Common materials include elastomers, engineered foams and viscoelastic polymers.
How do vibration damping materials reduce noise?
Vibrating panels, housings and other components can radiate sound. Damping materials absorb and dissipate some of that vibrational energy, helping reduce structural vibration and resulting noise.
What is the difference between vibration damping and vibration isolation?
Damping reduces vibrational energy within a component or structure, while isolation reduces the amount of vibration transferred from one component or structure to another. Many applications use both.
Which materials are commonly used for industrial vibration control?
Common materials include polyurethane elastomers and foams, PET fiber mats, polyethylene foam, silicone foams and sponges, neoprene, EPDM and viscoelastic materials. Selection depends on load, temperature, vibration frequency, compression and environmental exposure.
Where are vibration damping materials used?
Common applications include sound-deadening pads, gaskets, seals, machinery interfaces, enclosure panels, housings, spacers, cushioning components and isolation components.
How do vibration damping materials help reduce mechanical wear?
By reducing vibration, movement and impact between components, damping materials can decrease repeated mechanical stress on bearings, fasteners, seals and surrounding components, supporting longer equipment life and reduced maintenance.
Posted by mevjen on | Comments Off on How Tooling Impacts the Quality of Your Plastic Extrusion
Consistent plastic extrusion quality depends on more than process control. Even with stable temperatures, controlled screw speeds and high-quality materials, extrusion performance ultimately depends on the tooling shaping the molten plastic.
In plastic extrusion, the die influences material flow, wall thickness, dimensional stability and how the profile behaves as it cools. When extrusion dies are poorly designed, worn or inadequately maintained, quality issues can develop that cannot always be corrected through process adjustments alone.
Understanding how tooling for plastic extrusion affects the finished profile, can help manufacturers prevent defects, reduce scrap and achieve more repeatable production.
Below are several common tooling-related extrusion problems and the engineering approaches used to address them.
How Die Design Impacts Plastic Extrusion Performance
Problem: Warping and Bowing of the Extruded Profile
Warping, bowing and other profile distortions are often associated with uneven or insufficient cooling. However, the design of the extrusion die can also play a significant role.
Die geometry that creates uneven wall thickness or unbalanced material flow can introduce internal stresses into the profile. As the material cools, those stresses may cause the extrusion to twist, bow or move out of tolerance.
When this occurs, the finished profile may no longer fit properly within its intended assembly, potentially creating installation challenges, poor fit or part-performance issues.
Solution: Engineering-Driven Custom Tooling
Working with an extruder like Climatech that provides engineering support can help identify potential design issues early in the development process. By evaluating profile geometry, material behavior and application requirements up front, engineering teams can design tooling that promotes balanced material flow and more consistent wall thickness.
This helps reduce internal stresses as the profile cools and improves dimensional stability after production. Properly engineered die design can play an important role in preventing warping and bowing before they result in costly quality or assembly issues.
Problem: Profile Expansion After Exiting the Die
Once molten plastic exits the extrusion die, it begins to relax. In some materials, this causes the profile to expand — a phenomenon commonly known as die swell.
Excessive or inconsistent die swell can create dimensional variation and push finished profiles outside of specification.
Several tooling factors can influence this behavior, including:
Die land length
Flow balance
Profile geometry
Material behavior and rheology
How the tooling accounts for material relaxation after exiting the die
If these factors are not properly considered during die development, a profile may leave the tooling differently than expected and become difficult to control downstream.
Solution: Tooling Designed for Predictable Material Behavior
Effective extrusion die design accounts for how the material will behave both inside the tooling and immediately after it exits.
By designing tooling that anticipates elastic recovery in the material, extruders can achieve more predictable dimensions and tighter tolerances — reducing scrap, rework and downstream adjustment.
Problem: Poor Surface Finish
A rough, scratched or uneven surface finish can have several possible causes.
Process-related conditions such as contamination, improper temperatures or cooling issues may contribute. However, when surface defects begin appearing on an established profile that has previously run successfully, the condition of the extrusion tooling should also be evaluated.
Residue buildup, scratches, nicks, burrs or other damage to the die surface can transfer directly onto the finished extrusion.
Beyond appearance, tooling damage can potentially affect profile dimensions, wall thickness and overall part consistency.
Solution: Ongoing Die Inspection and Maintenance
Extrusion dies are production tools and require ongoing care.
Repeated manufacturing runs can eventually introduce buildup, wear or minor surface damage. Without regular inspection and maintenance, these conditions can continue to appear in the finished profile.
A disciplined tooling maintenance program may include:
Cleaning dies after production runs
Removing material buildup or residue
Inspecting surfaces for nicks, burrs or scratches
Polishing or buffing worn areas when appropriate
Inspecting critical dimensions
Properly storing tooling between production runs
Routine maintenance helps preserve surface quality, dimensional consistency and the useful life of the tooling.
Why In-House Extrusion Tooling is Key to Quality
For custom plastic profiles, tooling development is closely connected to the extrusion process itself.
Having engineering, tooling and production teams working together allows adjustments to be made based on how the material actually processes, rather than treating the extrusion die as a standalone component.
In-house tooling capabilities can also provide greater control over:
Die design and development
Tooling modifications
Maintenance and repair
Dimensional adjustments
Production troubleshooting
Lead times for tooling changes
This integrated approach can be especially valuable during new product development, when several iterations may be required to move from an initial profile concept to repeatable production.
High-Quality Extrusions Start With Strong Tooling
Reliable, repeatable plastic extrusions depend on more than a well-controlled extrusion setup. Extrusion die design, fabrication and maintenance all influence surface quality, dimensional stability and long-term profile performance.
At Climatech, our plastic extrusion capabilities are supported by an in-house machine shop and engineering expertise. This allows us to maintain greater control over tooling development, modifications and die quality throughout the life of a program.
By combining custom extrusion tooling, engineering support and controlled manufacturing processes, Climatech helps customers develop profiles designed for consistent performance from initial development through full production.
Learn more about Climatech’s plastic extrusion capabilities or reach out to an expert to discuss your next custom profile application.
Frequently Asked Questions About Tooling for Plastic Extrusion
How does tooling affect plastic extrusion quality?
Extrusion tooling controls how molten plastic flows and forms into the finished profile. Die design can influence wall thickness, dimensional consistency, surface finish and how the profile behaves as it exits the die and cools.
What role does die design play in extrusion defects?
Die geometry influences material flow and profile formation. Uneven wall thickness, unbalanced flow or improper die dimensions can contribute to warping, dimensional variation, surface defects and out-of-tolerance profiles.
Can extrusion defects be fixed by adjusting the process instead of the die?
Some extrusion issues can be improved by adjusting temperature, screw speed, cooling or other process conditions. However, defects caused by die geometry, tooling damage or wear typically require tooling modification, repair or maintenance to address the root cause.
What causes warping or bowing in plastic extrusions?
Warping and bowing can result from uneven cooling, inconsistent wall thickness or internal stresses created by unbalanced material flow. Both extrusion setup and tooling design should be evaluated when diagnosing these issues.
What is die swell in plastic extrusion?
Die swell occurs when molten plastic expands after exiting the die as internal stresses are released. Excessive or inconsistent die swell can push profiles out of tolerance and is influenced by die geometry, material rheology and flow balance.
Posted by mevjen on | Comments Off on What Makes a Great Seal for RVs?
RV design is about creating comfort, freedom and peace of mind — a home away from home where customers can relax, explore and enjoy the journey.
Once an RV creates that connection with its owner, protecting that experience becomes just as important. And often, that protection comes down to some of the smallest components on the vehicle.
RVs and other recreational vehicles operate in demanding environments. Rain, temperature swings, UV exposure, road vibration, dust, debris and long periods of storage can all take a toll over time.
That’s where gaskets and seals come in.
The right sealing solution helps protect your RV from water intrusion, reduce noise and vibration, keeps out unwanted pests and maintains the fit and finish customers expect for years to come.
Common Sealing Problems in RVs
A good RV seal does more than close a gap. It helps prevent small problems from becoming expensive ones.
Water Intrusion
Water is one of the biggest threats to an RV.
As seals around windows, doors, rooflines and slide-outs begin to wear or lose compression, even a small opening can allow moisture to enter the vehicle. Over time, that moisture can contribute to mold, structural damage, exterior panel delamination, damaged insulation and electrical problems.
A properly designed seal maintains contact between mating surfaces and continues providing a barrier despite movement, vibration and changing weather conditions.
Noise and Vibration
The comfort of an RV is about more creating a home away from home.
The fastest route to disrupting a good RV experience is excessive noise, vibration and harshness (NVH). Road travel introduces continuous vibration and shock loads that can cause rattling, material fatigue and premature wear.
Onboard equipment that makes an RV feel homey such as generators, pumps and HVAC systems can, ironically, add more unwanted vibration and noise. Without effective sealing and vibration isolation, these forces can degrade comfort, accelerate component failure and diminish the sense of quality RV owners expect.
Pest and Insect Intrusion
An RV sitting in storage can quickly become an inviting shelter for unwanted guests.
Small openings around slide-outs, vents, doors, utility penetrations and underbody components can provide enough space for insects, mice and other pests to enter.
Once inside, pests can damage wiring, insulation, upholstery and other interior components.
Effective sealing helps close these potential entry points while still accommodating the movement and tolerances required throughout the RV.
So, What Makes a Great RV Seal?
There is no single material or gasket design that is right for every RV application.
A great seal is designed around where it will be used, what it will be exposed to and how it needs to perform throughout the life of the vehicle.
Here are some of the most important characteristics to consider.
Long-Term Compression and Recovery
Many RV seals spend much of their life under compression.
Windows, doors, roof assemblies and slide-outs all rely on sealing materials that can compress when needed and recover their shape when the load is removed.
If a material develops excessive compression set, it may no longer maintain enough sealing force. That can create gaps that lead to leaks, rattles and reduced performance.
Materials commonly considered for these applications include:
EPDM closed-cell foam
Silicone foam and sponge
Neoprene/EPDM/SBR blends
Microcellular polyurethane foams
PVC foams
Polyurethane foams
The best choice depends on the amount of compression, temperature exposure, weather resistance and movement required by the application.
Vibration Isolation and Noise Reduction
A quieter RV requires managing vibration throughout the entire structure.
Gaskets and foam components can help isolate surfaces from one another, absorb road shock and reduce the movement that creates squeaks, buzzes and rattles.
Common materials used for vibration and noise control include:
Solid and sponge EPDM
Neoprene rubber
Microcellular polyurethane foam
Melamine foam
Polyurethane foams
Viscoelastic damping materials
PVC/nitrile blended foams
Butyl
Compression molded dampers
Choosing the right material involves understanding not only how much vibration is present, but also where it is coming from and how the surrounding components interact.
Durability in Outdoor Environments
The best RV seals are built for exposure. They resist UV degradation, temperature extremes, moisture and airborne contaminants without cracking, hardening or breaking down. Durable materials protect interior spaces while reducing warranty claims, service needs and long-term maintenance costs.
Proven materials for outdoor RV sealing can include:
3M VHB Tape
Solid EPDM rubber
Solid silicone rubber
PVC/Nitrile blended foams
Reliable Adhesion
Even a high-performance gasket cannot do its job if it doesn’t stay where it belongs.
Pressure-sensitive adhesives are commonly used to attach gaskets and seals to metal, plastic, painted surfaces and other RV substrates.
A successful adhesive system needs to account for factors including surface energy, temperature, vibration, environmental exposure and the stresses placed on the gasket during use.
Common options include high-performance acrylic adhesives, transfer adhesives and acrylic foam tapes such as 3M™ VHB™ tape.
Internal link: [Note: Using pressure sensitive adhesive as anchor text, link to blog #4 Guide to PSAs when it’s live]
Flexibility for Custom Designs
RV sealing applications are rarely one-size-fits-all.
Windows, doors, slide-outs, storage compartments, roof assemblies and interior components can all have unique shapes, tolerances and performance requirements.
That makes manufacturing flexibility especially important.
Materials that can be custom extruded, die cut or fabricated allow manufacturers to create sealing components that fit the application rather than forcing the application to fit an off-the-shelf gasket.
Solutions can include:
Custom profile extrusions
Precision die-cut and kiss-cut components
Adhesive-backed seals and gaskets
Fabricated components for complex assemblies
Custom shapes and multi-material constructions
When the material, geometry, adhesive and manufacturing process are considered together, the result can be a more reliable sealing system and a more efficient assembly process.
Better RV Sealing Starts with the Right Solution
The right RV seal is more than choosing a material from a specification sheet.
It starts with understanding the application.
How much compression is required? What temperatures will the seal experience? Is it exposed to UV or moisture? What surfaces need to be bonded? How much movement and vibration will occur?
Those questions help determine the material, profile, adhesive and manufacturing process best suited for the job.
Climatechbrings the capabilities and expertise — including die-cut converting, plastic extrusion, molded components selection and engineering support — to deliver long-lasting seals that minimize warranty claims and maximize the reliability and quality your customers expect.
Whether the goal is preventing water intrusion, reducing noise and vibration, improving attachment or developing a custom gasket for a challenging assembly, our team can help design a solution around the application.
Frequently Asked Questions About RV Seals and Gaskets1. What materials are commonly used for RV seals and gaskets?
Materials to improve RV sealing include EPDM closed-cell foam, silicone foam and sponge, solid EPDM rubber, microcellular polyurethane foam, PVC Foam and neoprene/EPDM/SBR blends.
Each offers different properties related to weather resistance, compression recovery, vibration isolation and temperature performance, so material selection should be based on the specific application.
2. Why do RV seals fail over time?
RV seals can deteriorate because of compression set, UV exposure, temperature extremes, moisture, repeated movement, vibration or adhesive failure.
As a seal loses elasticity or adhesion, gaps may form that allow moisture, air, dust or pests to enter the vehicle.
3. How do RV seals help reduce noise and vibration?
Seals and gaskets help isolate components and absorb movement caused by road travel and onboard equipment.
Materials such as elastomeric rubbers, butyl, microcellular foams, flocking tape and viscoelastic damping can reduce component-to-component contact and help control rattles, buzzes and structural vibration.
4. What areas of an RV are most vulnerable to sealing problems?
Common areas include windows, slide-outs, rooflines, exterior doors, storage compartments, undercarriage openings, vents and generator or equipment compartments.
These areas often experience frequent movement, environmental exposure or a combination of both.5. What is the difference between open-cell and closed-cell foam for RV seals?
Closed-cell foam is typically better suited for exterior sealing because its structure limits water absorption and provides stronger resistance to environmental exposure.
Open-cell foam is generally more appropriate for protected interior applications where cushioning or sound absorption is more important than creating a moisture barrier.
Posted by mevjen on | Comments Off on Your Guide to Choosing the Right Pressure Sensitive Adhesive for Your Application
Advances in pressure-sensitive adhesives (PSAs) have helped OEMs simplify product design, reduce mechanical fastening and support faster, more efficient assembly.
From fastening thermoplastic window components to sealing appliance gaskets or adhering plastic extrusions on recreational and powersports vehicles, PSAs play a critical role in modern product design.
Selecting the right adhesive, however, requires more than choosing a tape with sufficient tack. Substrate, temperature, environmental exposure, expected bond life and assembly requirements all influence long-term performance.
Most pressure-sensitive adhesives fall into three primary categories: acrylic, rubber and silicone. Each offers a different balance of adhesion, durability, temperature resistance and cost.
Understanding those differences is the first step toward choosing the right PSA for your application.
To narrow the field, here are the key factors to consider.
Types of pressure-sensitive adhesive
Acrylic-based adhesive tape
If you’re looking for strong, long-lasting bonding performance, acrylic-based PSAs are often the preferred choice, especially for demanding outdoor and industrial environments. Acrylic-based PSAs are also commonly used in die cut adhesive components where long-term performance is critical.
Key properties of acrylic adhesive tape
Bonds to a broad range of materials, including metals, glass, painted surfaces and many plastics
Performs across a wide range of operating temperatures
Develops bond strength over time
Resists UV exposure, weathering and temperature extremes
Creates clean, seamless bond lines that support sleek product designs
Available in specialized formulations for low-surface-energy materials
Rubber-based adhesive tape
Rubber-based adhesive tapes are well suited for rapid assembly and indoor applications.
Key properties of rubber adhesive tape
High initial tack allows components to reach handling strength quickly
Can adhere well to rough, uneven and certain low-surface-energy materials
Cost-effective compared to acrylic and silicone options
Generally offers a narrower temperature and environmental performance range than acrylic adhesives
Silicone-based adhesive tape
Silicone PSAs are typically used in applications requiring extreme temperature resistance or adhesion to difficult silicone-based substrates.
When comparing acrylic and silicone adhesives, silicone systems generally offer broader temperature capability and strong resistance to demanding environmental conditions.
Key properties of silicone adhesive tape
Performs across very high and very low temperature ranges
Bonds effectively to silicone and other difficult substrates
Resists UV exposure, ozone, moisture, chemicals and solvents
Offers high dielectric strength for electrical insulation and shielding
Conforms to irregular or complex surfaces
Available in formulations that allow repositioning or clean removal
Key factors when selecting a pressure-sensitive adhesive tape
Surface energy of the substrate
Surface energy influences how well an adhesive wets out across the surface and develops a bond.
Materials are commonly grouped into high-, medium- and low-surface-energy categories.
High surface energy materials include:
Aluminum
Glass
Stainless steel
Medium surface energy materials include:
PVC
Nylon
Polyurethane
ABS
Painted surfaces
Low surface energy materials include:
Polyethylene
Polypropylene
Certain powder-coated surfaces
PTFE
Low-surface-energy materials are generally more difficult to bond because the adhesive does not spread across the surface as easily.
Best bonding solutions for low-surface-energy materials:
Rubber-based tapes: Provide fast initial tack and quick handling strength, though performance is limited in harsh environments
Acrylic-based tapes: Certain formulations, including low-surface-energy (LSE) acrylics, are engineered to provide stronger, more durable bonds to materials such as polypropylene, polyethylene and other challenging substrates.
Operating environment
Environmental conditions can have a significant effect on adhesive performance.
Consider:
Minimum and maximum operating temperatures
Indoor versus outdoor use
UV exposure
Moisture and humidity
Chemical or solvent exposure
Vibration or movement
Thermal cycling
Longevity and bond life
The expected life of the bond is another important consideration.
For long-term or permanent applications, acrylic adhesives are often selected because of their resistance to aging, UV exposure and environmental conditions.
Rubber-based systems may be appropriate when fast assembly, initial tack or shorter-term performance is more important.
The correct choice depends on the substrate, environment and service requirements of the finished product.
Choosing the right PSA format
PSA tape is designed to speed up production while delivering a reliable, long-lasting bond. To get the most value from it, you’ll want to select the format that best fits your assembly process and performance requirements. Working with a custom fabricator like Climatech can help you save time, reduce material waste and simplify installation.
Adhesive transfer tape
Adhesive transfer tape consists of pressure-sensitive adhesive supplied on a release liner without a permanent carrier.
Because there is no carrier, transfer tape creates a very thin bond line with minimal added thickness.
This format is often used when:
A low-profile bond is required
Adhesive is laminated to foam, film or another substrate
Flexibility and conformability are important
Custom shapes are needed for assembly
Transfer adhesives can be laminated to other materials and die cut into precise shapes for repeatable installation in OEM production.
Double-sided tape
Double-sided tape contains adhesive on both sides of a carrier.
The carrier provides additional structure and dimensional stability while also helping control adhesive thickness and handling during assembly.
Double-sided tapes are commonly used for:
Mounting
Gasketing
Sealing
Cushioning
Component attachment
Certain high-performance constructions, including acrylic foam tapes such as 3M™ VHB™ Tape, can also be used in applications requiring durable bonding, load distribution and environmental resistance.
Single-sided tape
Single-sided tape consists of pressure-sensitive adhesive applied to one side of a carrier such as film, foam, foil, cloth or paper.
The carrier provides structure, strength or additional functional properties.
Common applications include:
Surface protection
Insulation
Masking
EMI shielding
Sealing
General-purpose bonding
Partner with an expert in pressure-sensitive adhesive fabrication
Choosing the right PSA involves more than selecting between acrylic, rubber and silicone.
Substrate compatibility, surface energy, temperature, environmental exposure, bond life, thickness and assembly requirements all need to be considered together.
Climatech supports OEMs throughout the design and development process with engineering guidance to help identify the right pressure-sensitive adhesive for each application. Our team combines material selection with adhesive lamination, precision die cutting, prototyping and production support to manufacture components designed for consistent, reliable performance.
FAQs about choosing pressure sensitive adhesive (PSA) tape
1. What are the main types of pressure-sensitive adhesives?
Most PSAs fall into three categories: acrylic, rubber and silicone. Each offers different advantages depending on the substrate, operating environment, temperature range and expected life of the bond.
2. When is acrylic adhesive tape the best choice?
Acrylic PSAs are often the go-to for long-term durability, especially in outdoor or industrial applications where resistance to UV, weathering and temperature extremes are important.
3. When is rubber-based adhesive tape best?
Rubber-based PSAs are commonly selected for rapid assembly because they offer high initial tack and quick handling strength, especially in many indoor applications and on certain low-surface-energy materials.
4. What does “surface energy” mean and why does it matter for tape?
Surface energy affects how easily an adhesive “wets out” and bonds. High surface energy materials (like metal and glass) are typically easier to bond, while low surface energy plastics (like polypropylene and polyethylene) can require specialized adhesive formulations.
5. What’s the difference between adhesive transfer tape and double-sided tape?
Adhesive transfer tape has no carrier—just adhesive on a release liner—so it’s ideal for ultra-thin bond lines and laminating to films or foams. Double-sided tape has adhesive on both sides of a carrier, which adds structure, dimensional stability and improves handling.
6. What information should I share with a fabricator to select the right PSA?
Share the substrate materials, surface condition, operating environment, temperature range, indoor or outdoor exposure, chemical/moisture exposure, desired bond life and preferred adhesive format. Part drawings, bond area, thickness requirements and assembly details can also help speed material selection and prototyping.
Posted by mevjen on | Comments Off on How Plastic Extrusions Improve Window Performance and Efficiency
Evaluating window performance is an exercise in problem solving. How do you let in what you want — natural light, ventilation, the view — while keeping out what you don’t?
For a truly effective window system, it’s important to look beyond the double-paned glass and understand where performance breaks down.
Air leakage, heat loss and moisture intrusion typically occur at the frame, joints and moving interfaces. This is where plastic extrusions play an essential role in improving the performance of the overall window system.
What are plastic extrusions in window systems? Plastic extrusion is a manufacturing process that creates continuous profiles with a consistent cross-section.
In window systems, extrusions are commonly used to help seal, insulate and protect window assemblies. Selecting the right extrusion material can improve energy efficiency, reduce maintenance and extend the life of the window system.
Where windows fail — and how plastic extrusions improve window performance
Sealing air and water infiltration
Air leakage is a major contributor to energy loss, while moisture intrusion can lead to premature window failure. Plastic extrusions used as seals and weatherstripping help create tight interfaces between window components that reduce drafts while keeping out rain and ice.
Properly designed extrusions maintain compression set through repeated opening and closing cycles, allowing seals to perform consistently over time.
Reducing thermal transfer
A major advantage of plastic is that it has low thermal conductivity, making it effective for limiting thermal transfer at interfaces within window frames. Extruded plastic components help reduce thermal bridging — particularly in systems with metal or composite frames — supporting improved energy efficiency.
By slowing the movement of thermal energy, plastic extrusions help stabilize interior temperatures and reduce heating and cooling losses.
Protecting against environmental exposure
Window components are exposed to UV, moisture, temperature fluctuations and debris. Plastic extrusions can be engineered to withstand these conditions, helping protect sealing surfaces and critical interfaces from degradation.
This protection supports long-term performance while reducing maintenance and replacement requirements.
Common window and door components made with plastic extrusions
Plastic extrusions are used across a wide range of window components, each serving a specific performance function within the window assembly.
Common examples include:
Weatherstrips and sweeps: Flexible PVC components that limit air infiltration at operable joints, providing a soft, pliable seal.
Jambliners: Vertical tracks made from vinyl in double-hung windows that support smooth operation while preventing air leakage and offering resistance to condensation.
Thermal breaks: Components that incorporate an extruded plastic profile to insulate between interior and exterior metal components. This insulation interrupts the path of thermal energy, reducing heat transfer between outdoors and indoors while resisting temperature fluctuations and condensation.
Glazing beads: PVC profiles used to secure glass panes while sealing out moisture, air and pests. These components resist warping, cracking and rotting after exposure to temperature differences, weather conditions and freeze-thaw cycles.
PD interlocks: Components that improve sealing and alignment in sliding window and door systems.
Each of these components relies on consistent profile geometry, material selection and tight tolerances so they can perform as intended with minimal maintenance over the life of the window.
Common plastic materials used in window extrusions
Window and door components are manufactured from a range of thermoplastic and composite materials, each selected based on performance requirements and environmental exposure.
PVC and CPVC: Commonly used for window seals, weatherstripping and frame components. These materials are durable and resist mold and condensation.
ABS: Commonly used as thermal break strips between aluminum panels to enhance insulation.
Capstock materials: Often applied to exterior-facing components to improve UV resistance and color stability.
Specialty Composite Polymers (SCP): Used in applications that require higher heat deflection temperatures or reduced thermal expansion.
Choosing the right plastic extrusion material
Before selecting a material, consider the following factors:
Temperature range: Materials must maintain flexibility and performance across a wide range of climate conditions, from subzero temperatures to triple-digit heat.
UV and weather resistance: Outdoor exposure demands materials that resist cracking, fading and degradation.
Compression set: Low compression set helps seals maintain effectiveness over repeated use.
Compatibility: Extrusions should integrate cleanly with surrounding frame materials and installation processes.
Longevity: Durable materials support longer service life and lower maintenance needs.
Ready to improve window performance?
Plastic extrusions play a critical role in window performance. Choosing the right extrusion material — and designing profiles around real-world conditions — helps ensure windows perform as intended throughout their service life.
Work with Climatech to design custom plastic extrusions that support sealing, insulation and long-term durability. Our team can help you select the right materials and profiles for your window or door application.
How do plastic extrusions improve window energy efficiency?
Plastic extrusions improve window energy efficiency by sealing gaps, reducing air leakage and limiting thermal transfer at joints and interfaces. Components such as window seals, weatherstripping and thermal breaks help prevent drafts and heat loss that commonly occur around window frames rather than through the glass.
Where do windows typically lose energy or fail?
Windows most often lose energy or fail at the frame, joints and moving interfaces. Air leakage, moisture intrusion and thermal bridging at these points can reduce performance over time. Plastic extrusions help address these weak points by providing consistent sealing, insulation and protection.
What window components are commonly made with plastic extrusions?
Plastic extrusions are used to manufacture many window and door components, including weatherstrips, sweeps, jamb liners, thermal breaks, glazing beads, PD interlocks and protective profiles. Each component plays a specific role in sealing, insulation, alignment, or durability.
Why is plastic a good material for window seals and weatherstripping?
Plastic is a poor conductor of heat and can be engineered to remain flexible over a wide temperature range. These properties make it well suited for window seals and weatherstripping that must maintain compression, resist moisture and perform reliably through repeated opening and closing cycles.
How do thermal breaks improve window performance?
Thermal breaks use insulating materials, often extruded plastics, to separate interior and exterior metal components in a window frame. This interrupts the path of thermal energy, reducing heat transfer, improving energy efficiency and helping limit condensation.
What plastic materials are commonly used in window extrusions?
Common materials used in window and door extrusions include PVC, CPVC, ABS, capstock materials and Climatech’s proprietary specialty composite polymers (SCP). Each material is selected based on factors such as flexibility, UV resistance, heat tolerance, dimensional stability and environmental exposure.
Posted by mevjen on | Comments Off on What You Need to Know About Designing Custom Plastic Extrusions
Lightweight, durable and highly adaptable — plastic extrusions expand the possibilities of your product design without adding unnecessary weight or complexity. From weather-resistant window and door profiles to appliance trim and RV components, plastic extrusions offer a level of flexibility that metal and other materials often can’t match.
But that flexibility also introduces design considerations that can’t be overlooked. Material selection, tooling, tolerances and prototyping all influence how a profile extrusion performs in the real world.
That’s why working with an experienced extrusion partner early in the design process matters. Manufacturers like Climatech offer engineering support alongside in-house tooling and extrusion capabilities, helping engineers and product teams navigate these decisions while reducing risk and streamlining the path from concept to production.
This guide outlines the key considerations for designing effective extruded profiles, so you can make informed choices at every stage of development.
Engineering support establishes a strong foundation for the plastic design process
When it comes to custom plastic extrusion design, you don’t have to go it alone. A manufacturer that offers engineering support can streamline the development of extruded profiles by identifying potential challenges early before they become costly changes.
Experienced extrusion engineers understand how material behavior, profile geometry, tooling and downstream processing work together. By collaborating early, you can optimize your design for manufacturability, speed up time to market and keep costs in check.
Refining material selection for your extrusion profile
Every extruded plastic profile begins with a polymer resin, each with its own molecular structure that influences strength, flexibility, durability and appearance. Choosing the wrong material can lead to cracking, breaking, surface imperfections or premature failure, especially under impact, pressure or extreme temperatures.
A high-quality extrusion manufacturer brings deep material expertise and access to a wide range of resins and specialty additives. This allows them to recommend a short list of viable material options based on performance requirements, aesthetics, environmental exposure and budget.
Performance-driven design of extruded profiles for system integration
Custom profiles offer the best integration and a cleaner, more functional design than off-the-shelf shapes. However, complex profiles can add time and cost if tooling and manufacturing constraints aren’t considered upfront.
Working with a manufacturer that has an in-house tool shop gives you greater visibility and control during this phase. Engineers and machinists collaborate closely to refine profile geometry, ensure proper material flow and minimize design revisions.
Manufacturers with a range of extrusion barrel sizes can also support a wide variety of profiles, from small, precision components to large, heavy-duty extrusions. In some applications, co-extrusion allows two or more materials to be combined into a single profile, delivering the right balance of rigidity, flexibility, sealing and wear resistance.
Striking a balance in plastic design with the right tolerances
Tight tolerances can improve fit and function, but they also increase cost. Plastic extrusions naturally experience dimensional variation due to polymer behavior during cooling and processing. Applying metal-like tolerances to plastic profiles often leads to excess scrap, longer production cycles and higher tooling costs.
Engineering support plays a critical role in evaluating how the profile will function in the final assembly. By analyzing the end use, mating parts and profile geometry, manufacturers can recommend tolerance ranges that balance performance requirements with efficient production.
Designing with uniform wall thickness to improve stability
Uneven wall thickness can compromise both part performance and appearance in plastic extrusions. Variations may cause bowing, warping or inconsistent cooling. These are issues that originate long before the profile exits the extruder.
Thoughtful tooling design and process control help maintain uniform wall thickness throughout the profile. Choosing a partner with the expertise to engineer uniformity into both the die and the extrusion process ensures consistent output and repeatable quality.
Prototype options for extruded profiles before full production
Prototyping allows you to validate material selection, profile geometry and fit before committing to full-scale production. Prototypes provide insights into real-world performance and help you identify refinements at the early stage when changes are faster and more cost-effective.
Climatech offers several prototyping options to help reduce risk and accelerate the path to full production:
3D Printing:
Used to approximate geometry design
Quick and inexpensive
Helpful for stakeholder reviews, assembly checks
Concept validation, internal approvals
Strip Die for Material Validation:
Useful for observing shrinkage and stability
Provides samples for physical testing, such as tensile, flex and impact
Validates the material behavior, not the final profile
Value-added services that support faster time to market
Beyond extrusion itself, value-added services can simplify your supply chain and reduce lead times. Fabrication services, including die cutting, drilling, machining, labeling, inline taping, laser printing and assembly, allow finished components to arrive production-ready.
A plastic extrusion partner that provides these value added services will reduce handling, improve consistency and keep projects moving efficiently from design through delivery.
Smarter extrusion design starts with Climatech
The key advantage of custom plastic extrusions is their versatility. When designed correctly, they deliver design freedom and lightweight strength across a wide range of applications.
Climatech is here to support your design process for custom plastic extrusions that not only fit the application, but function reliably in the environments they’re designed to serve.
If you’re early in the design process or looking to improve an existing profile, connect with our team to explore how a partnership with Climatech can streamline development and manage costs — without sacrificing performance.
Posted by mevjen on | Comments Off on Everything You Need to Know About Custom Die Cut Components
Though small and often unseen, custom die cut components play a critical behind-the-scenes role in product performance. They seal out moisture, silence vibrations and rattles, absorb impact and insulate against heat. Above all, they hold everything together.
When made from the right combination of foam, rubber and pressure-sensitive adhesive — and cut with a tailor fit — they can make all the difference on product performance.
We’ll explore what these parts are, where they’re used, and how working with the right fabricator can strengthen the overall quality of your design.
What are custom die cut components?
Die cut components are small, customized parts used to assemble the larger systems within your product. They’re typically made from flexible, non-metallic materials such as foam, rubber, plastic, silicone and can be applied with a pressure-sensitive adhesive or fastener.
Cutting methods: The term “die cutting” is often used as a catch-all, but not all components are cut with metal dies. Fabricators use automated equipment that may include steel-rule dies or software-guided cutting systems to convert sheets and rolls of material into precise shapes that match your assembly’s design and dimensions.
Functionality: Depending on their function within the assembly, these components may provide sealing, sound absorption, cushioning, thermal, vibration dampening — or a combination of these.
Value of custom components: Working with a converter to make your die cut components can save you time and money. Compared to manually cutting materials in-house, they improve consistency, reduce waste, optimize efficiencies and speed up production. With an adhesive backing made from 3M™ tape they also simplify installation on the production floor.
What are the differences between die cutting and CNC cutting?
A high-quality fabricator will determine the best method from multiple cutting technologies to meet your needs. Here’s a comparison of two common fabrication processes:
Die cutting
Uses a custom steel rule die to stamp out parts from sheet or roll materials
Offers the highest throughput, making it ideal for high-volume or repeat production
Delivers tight tolerances and clean edges when matched with the right press type (flatbed, rotary, or kiss-cutting)
Requires tooling, which can add upfront cost and lead time—but lowers the cost per part in large runs
Best for shapes or designs that don’t change often
CNC cutting (Dieless cutting technology)
Uses a software-guided blade to cut material on a vacuum table. No die required reducing upfront cost and lead time.
Ideal for prototypes, frequent design changes and short production runs
Supports complex shapes and fine detail with a multihead tool that includes oscillating knives and router bit for non-metallic materials such as foams and plastic.
Employs nesting software to maximize material usage and reduce scrap
Better suited for thicker or harder-to-cut materials, such as packaging products
Applications of die cut components across industries
A key advantage of die cut gaskets is how they make it possible to join dissimilar materials, including metal, glass and plastic, leaving a smooth, seamless surface.
These components can also be specially designed to provide additional functionality and protection for your products. Here are a few application examples of frequently used materials:
Sealing and Gasketing
Die cut seals and gaskets use materials with low compression set and pressure-sensitive adhesives to create tight, protective seals. These components help safeguard internal parts from dust, moisture, air, and other contaminants. Foam tapes such as 3M™ VHB™ can also be used to bond dissimilar materials together and remove the need for mechanical fasteners.
Best materials: Microcellular Polyurethane, Ensolite SF0, Neoprene or EPDM Sponge, Silicone foam, XLPE, PVC, 3M™ VHB™ and solid sheet rubber.
Vibration, Noise Dampening and Sound Absorption
When it comes to reducing vibration and noise in equipment, non-metallic materials can provide an effective solution. Specialty foams are designed to absorb or dissipate these vibrations to reduce noise and improve acoustic performance. This leads to quieter operation and a better end-user experience in vehicles, appliances and industrial equipment.
Best materials: 3M™ Thinsulate, PET Needle Punched Fiber, Melamine, Polyurethane Foam and rubber, Polyethylene Foam, EVA Foam, Mass Loaded Vinyl and Sheet Rubber
Cushioning
Die cut foams and adhesive-backed materials provide shock absorption and impact protection, especially important in Electronics and Industrial Vehicles.
Best materials: Microcellular Polyurethane, XLPE, Silicone Foam, Neoprene and EPDM Foam open-cell foams such as Polyester.
Thermal Insulation
Fiberglass, foam and thermal shields can help prevent unwanted heat transfer between components, a critical feature in electronic devices, HVAC and high-temperature environments.
Best materials: Silicone Sponge, PVC/NBR/EPDM Foam, Polyethylene Foam, Basotect Melamine, Fiberglass, Ceramic and Aluminum Foil
Die cut components: How are they manufactured?
Die cut components are typically produced through a multi-step process. Here’s a high-level look at the typical workflow of how custom fabrication goes from concept to finishing.
Engineering support: Before the first cut, each project should start with design review, including the material selection. Engineering input ensures your part meets performance requirements and minimizes rework.
Lamination: Layers of material, often foam or rubber along with a pressure-sensitive adhesive, are bonded together using heat, pressure or both. This creates a composite ready for cutting, typically with a protective liner for clean handling.
Slitting: Wide sheets or rolls are slit into narrower widths, either as a prep step for die cutting or to create ready to use custom-sized rolls.
Cutting: Based on the material and production volume, the most appropriate cutting method is used: Die cutting for high-volume jobs that can be kiss cut on a roll, individual die cut or CNC dieless cutting for prototypes and/or complex shapes.
Finishing: Value-added services like labeling, assembly, kitting, and inventory support help streamline assembly and simplify your supply chain.
Ready to get started?
Choosing the right fabrication partner can make a measurable difference in your product, including its cost-efficiency, lead time and performance. From material selection to on time part delivery, a full-service partner like Climatech can streamline your process while maintaining tight tolerances and providing you the highest level of quality.
With our value-added services like kitting, labeling and engineering guidance, you’ll spend less time managing the details and more time moving your product forward.
Contact the team at Climatech to discuss your next project or request a quote.
FAQs about custom fabricated components
1. How do fabricators maintain tight tolerances in complex die cut parts?
Die-cutting complex parts with tight tolerances requires a meticulous approach, encompassing several key factors and techniques to ensure accuracy and precision.
Material selection
Understanding material properties: Choosing the right material is crucial. Factors like thickness, hardness, flexibility, and composition significantly influence the cutting process.
Balancing flexibility and rigidity: Materials with the right balance are ideal. Too much flexibility or thickness can lead to distortion, while excessive rigidity might result in unclean cuts.
Die design and manufacturing
CAD software for precision: Detailed 3D models and precise dimensions are created using computer-aided design (CAD) software.
Precision die manufacturing: Dies are crafted using high-precision techniques to achieve the necessary accuracy and intricate shapes.
Appropriate rule height: For steel rule dies, selecting the correct rule height based on material thickness and desired cut quality is crucial.
Precision machinery and optimization
CNC cutting machines: CNC machines offer precise control over cutting, reducing human error and ensuring repeatability.
Optimizing machine settings: Adjusting cutting speed, pressure, feed rate, and other parameters based on the material and desired outcome is crucial for precise cuts.
2. What’s the difference between Die Cutting and CNC Cutting?
Die cutting uses a steel rule die to stamp parts at high volume, making it ideal for repeat production. CNC cutting uses a software-guided blade or router bit without the need for custom tooling, making it well suited for prototypes, intricate shapes and short runs.
3. What materials are best for sealing in high-temperature environments?
Silicone rubber, graphite, non-asbestos compressed gaskets, EPDM, and high-performance closed-cell foams are commonly used for seals that need to withstand heat, chemicals, and environmental exposure.
4. How can I reduce lead times when ordering custom die cut parts?
With our full-service in-house engineering, inventory management, and just-in-time shipping we can help reduce lead times and improve supply chain efficiency. Our CNC cutting machines can also avoid tooling to reduce initial production and prototype lead time.
5. What are the cost advantages of sourcing custom fabricated parts from a single partner?
Vendor consolidation can lead to greater cost advantages due to streamlined communication, simplified administration, improved efficiency, better quality control, and the potential for leveraging purchasing volume.
