Custom Die Cutting Services
Providing Precision Custom Die Cutting and Unmatched Customer Service for 75 Years
If you are in need of custom die cutting for either a component or product, our team of experts stands ready to work with you to create the perfect end result. We assist you in design development, prototype preparation, quality control, and post-production logistical needs such as packaging. Our custom die-cutting services follow a 4-step process.
Or call Josh at (707) 769-4488
Custom Die Cutting Process
Step #1: Design (1-3 Days)
During the design phase of the project, we work with the customer to either create a prototype or turn their existing prototype into a die-cut design. We select a die-cutting method, typically rotary or flatbed, that will work best to accomplish your needs for precision, tolerance level, and cost-effectiveness for the needed quantity of production. At the end of the design phase, the completed prototype will be tested within the broader use case of the component or product to ensure the design passes all functional requirements.
Step #2: Die Creation (2-7 Days)
Once the product/component design has been approved, we begin the die creation phase. In this phase, we custom-tool the dies to produce the product at scale through rotary or flatbed die cutting. All dies are tooled by some of the top die tooling experts in the world to ensure reliability, preciseness, and quality. All dies are created with high-grade steel to ensure an accurate replication of the approved design.
Step #3: QMS Approvals (at Customer Discretion)
Before we begin full-scale production, we create initial product samples to be sent through QMS (quality management system) approvals. Tolerance level tests, overall dimension tests, and fit and function tests are performed. If product refinement is necessary, we will do so and repeat step number two until the design perfectly suits your needs.
Step #4: Production (Quantity Dependent)
Once the final approval is obtained, full-scale production begins. We are highly efficient and have a relentless focus on meeting your deadlines and quality standards. We continually check products as they are produced to ensure the standard of quality is maintained. A continual flow of communication with the customer is maintained regarding their production and shipping status, which is one of the many reasons our customers have been loyal to us for decades.
Stocking & Packaging
We also provide stocking and packaging services for customers in need of them. We frequently work with customers using Kanban, JIT, End to End, and other stocking programs to ensure stock levels remain at the desired levels. Additionally, if high-end user packaging such as blister packs, shrink wrapping, custom boxes, or OPFs are needed, we will package the products and ship them directly to the distribution centers.
Or call Josh at (707) 769-4488
Choosing a Custom Die-Cutting Method
Most customers will utilize either our rotary or flatbed die-cutting service. We aid in selecting the best option during our design process based on your design specifications and quantity. The table compares rotary and flatbed die cutting.
| Rotary Die Cutting | Flatbed Die Cutting | ||
|---|---|---|---|
| Pros | Cons | Pros | Cons |
| Suitable for high-volume orders providing economies of scale | Higher setup costs making it less economical for small batches | More adaptable for low to medium volume without high setup costs | Slower production rates can lead to longer turnaround times |
| Consistently high precision ideal for complex and detailed designs | Limited to materials in roll form reducing material options | Capable of handling a wider variety of materials and thicknesses | Higher material waste due to spacing between cuts affecting cost |
| Efficient material utilization reducing waste and costs | Changes in project scope or design can be costly and complex to implement | Flexibility in setup allows for customization and changes in design | Operation can increase labor costs due to material handling |
| Faster turnaround times for large orders | Typically requires a long-term commitment due to setup investment | Often more cost-effective for short runs and prototypes | Less suitable for very high-volume jobs due to slower speeds |
Or call Josh at (707) 769-4488
Tailored Solutions for Complex Designs
Many customers come to us with complex designs or specifications that other companies are not able to fulfill. In our 75 years of die cutting, there have been very few designs we could not handle. We boast a large material catalog and are specialists in many areas of die-cutting.
Our Material Expertise
While we specialize in thin gauge film and sheet plastics, we are experts in working with the following material types.
| Paper | Polyester Films |
|---|---|
| Foam | Rubber |
| Foil | Adhesives |
| Plastics | Fabric |
| Composites | Felt |
| Fiberglass | Silicone |
| Metallic Foil | Nonwovens |
Or call Josh at (707) 769-4488
Technological Capabilities
We specialize in each of the following technological capabilities. This gives us a wide range of production options to choose between in creating the highest quality end result possible for our customers.
- Servo-driven presses
- Line-driven presses
- Small scale lamination
- Narrow gauge lamination
- Narrow web
- Wide web
- Die cut in register
- Lamination
- Metal to metal cutting
- Kiss cutting
- Roll to roll capabilities
- Narrow web slitting
Or call Josh at (707) 769-4488
Custom Die Cut Products Produced
We have partnered with our customers to produce the following products:
| Lenses and lens accessories | Gaskets |
| Seals | Decorative leather |
| Shims | Face shields |
Or call Josh at (707) 769-4488
Production Capability Overview
We have the expertise and machinery to complete a wide range of custom die-cutting projects. We’ve included a detailed overview of our key production specifications below.
| Category | Rotary | Flat Bed |
|---|---|---|
| Maximum Product Width | 16 inches (we can slit down larger jumbos) | 40 inches |
| Maximum Product Thickness | .015 inches (flexible with different materials) | .5 inches (material dependent) |
| Tolerance Level | ±0.005 inches | ±0.010 inches (material dependent) |
| Maximum Production Capacity | 40,000 units/hour (size dependent) | 2,000 - 4,000 parts/hour (size dependent) |
| Average Lead Time | 3 weeks | 3 weeks |
Or call Josh at (707) 769-4488
Frequently Asked Questions
What is the difference between rotary and flatbed die cutting? Which one is right for my project?
Generally, rotary die cutting will work best for high-volume orders and works for cutting materials that come in roll form. Flatbed die cutting is more suitable for medium and low production volumes and can handle a wider variety of materials and thicknesses. We help you choose the best option for you during our initial consultation.
Can I submit my own drawings?
Absolutely! If you supply a drawing in a .DXF format or a dimensioned .PDF format in a 1:1 ratio, we can die-cut the product. We also accept .IGES, .STL, .OBJ, .STEP, and .DWG files.
Can my company supply materials to be die cut?
Yes! While we have a large amount of materials stocked to be cut, we can also cut materials from your company if necessary.
Can you accommodate urgent or rush orders?
Depending on the specifications of your project, we can have dies ready as soon as the next day to begin producing your order.
Getting Started
To request a quote or ask any questions you may have, please click the button below to visit our request a quote page or call Josh at (707) 769-4488.
Or call Josh at (707) 769-4488