Die cutting is a very efficient and low cost way to cut foam into various custom shapes and sizes. It can work with almost every foam materials. This fabrication method also applies to fabrication of plastic, paper, felt and so on. According to product electronic drawing, a steel die mold is needed to made before die cutting process. With the die mold made, the required foam shapes and sizes can be easily made by die cutting machinery.

Generally we can provide three main die cutting fabrication services such as steel rule die cutting, kiss cutting and rotary die cutting.

Steel Rule Die Cutting

There will be 3 essential parts when using steel rule die cutting. They are metal made cutting blades, flat die mold board and rubber ejection layer. With the 3 parts working together, a steel rule die cutter can efficiently stamp out materials shape. Steel rule die cutting is a very typical foam fabrication technique. It is quite suitable for cutting thick foam sheet and small quantity order with low cost tooling cost.

Kiss Cutting

Kiss cutting is a shallow cut on foam materials, and leaves finished foam parts on a removable layer, usually paper liner or film. The finished foam parts will stay on the removable layer for easy usage. Since it is a shadow cut, kiss cutting is suitable for fabricating thin foam materials. It is usually used for producing custom foam pads, gaskets and industrial insulation layers.

Rotary Die Cutting

Due to its high speed productivity, rotary die cutting is often used for fabrication large volume foam parts. It is a very simple process, which is like a flat foam material runs through a die that is continually rolling in place. The cutting blade edge pinches foam material and pushes out the part in its desired shape. Rotary die cutting is also a very precise fabrication method for making custom foam parts, which is highly recommenced to work with ultra thin foam material such as PVC foam, EPDM foam and cross-linked Polyethylene foam.