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.