Best Occupational Health and Safety Die-Cutting Services
At Colvin-Friedman, we have been producing top-quality die-cutting components since 1949, with many of those components being used for OSHA applications. Our understanding of this industry leads us to three primary areas of focus: precision in cutting, deep expertise in materials commonly used for OSHA products, and the continual development of best practices to ensure components are produced to exacting tolerances. Below we’ve listed some of our capabilities, best practices, and more information on our process. If you would like a quote on your occupational health and safety die-cutting needs, fill out the quote form or call our Vice President, Josh Rodman at 707-769-4488
Or call Josh at (707) 769-4488
OSHA Product Materials by Type and Die Cutting Process
Below we’ve listed categories of material that we can die cut, with an emphasis on explaining the differences in methods: rotary die cutting can be used for very high-speed production, but the level of detail and thicknesses of material that can be processed is different than that of flatbed steel-rule die cutting.
| Material Type | Products | Example Materials | Preferred Die Cutting Method |
|---|---|---|---|
| Optical Materials | Thin lens overlays, Protective films, Disposable face shield covers | Thin polycarbonate films, PET optical grade films, Removable protective layers | Rotary for high-speed cutting of thin films up to .015"; Flat press for thicker materials |
| Plastic Films and Sheets | Lens care product packaging, Thin protective overlays, Instruction manual pages | PET (polyethylene terephthalate), LDPE (low-density polyethylene), Thin PETG sheets | Rotary for high-speed cutting of films up to .015"; Flat press for thicker materials or intricate designs |
| Foam and Cushioning Materials | Thin foam gaskets, Adhesive-backed foam tapes | Thin closed-cell polyethylene foam, Adhesive-backed foam tapes up to .015" | Rotary only for very thin foams up to .015"; Flat press for all thicker foams |
| Rubber and Elastomers | Thin gaskets, Membrane switches, Thin seals | Thin silicone sheets, Thin neoprene gaskets, Elastomeric films up to .015" | Rotary for thin sheets up to .015"; Flat press for thicker materials and most OHS applications |
| Abrasive Materials | Thin sanding sheets, Fine polishing films, Thin abrasive overlays | Thin aluminum oxide sheets, Fine-grit sanding films, Thin non-woven abrasive materials | Rotary for materials up to .015"; Flat press for thicker or more aggressive abrasives |
We are also capable of working with far more material thicknesses with our flatbed die-cutting processes. Below are some of the expanded capabilities you might find with these production systems in use at Colvin-Friedman.
| Material Type | Suitability | Examples of Viable Products |
|---|---|---|
| Optical Materials | Excellent | Full-thickness lenses up to 0.5”, Face shields, Multi-layer protective eyewear |
| Plastic Films and Sheets | Excellent | Thick protective overlays, Robust face shield materials, Lens care product containers |
| Foam and Cushioning Materials | Excellent | Goggle padding, Helmet inserts, Ear protection components, Thick cushioning materials |
| Rubber and Elastomers | Excellent | Thick valve components, Robust seals and gaskets, Complex respirator parts |
| Abrasive Materials | Very Good | Thick sanding discs, Durable polishing pads, Multi-layer abrasive sheets |
Or call Josh at (707) 769-4488
Best Practices for Die-Cut OHS Materials by Type
Since each of the materials used in creating occupational health and safety products has differences in tensile and compression strength, chemical and temperature resistance, and more, working with each one requires a different set of conditions. Below, we’ve listed what helps Colvin-Friedman maintain its standard of excellence and quality control.
Optical Materials
| Issue | Expert Practice |
|---|---|
| Optically clear edges on cut lenses | Use polished and ultra-sharp dies, and when necessary, implement polishing procedures. |
| Preventing scratches during the cutting process | Use protective films when necessary and maintain clean room protocols. |
| Maintaining designed curvature | Use specialized curved dies and ensure temperatures meet material specifications to reduce warping. |
Plastic Films and Sheets
| Issue | Expert Practice |
|---|---|
| Avoiding micro-cracks and fissures | Maintain optimum pressure and test different speeds for cutting on prototypes. Use extremely sharp dies designed for specific plastic types. |
| Preventing static build-up and debris accumulation | Use ionizers throughout the production cycle and include anti-static packaging for finished parts before inventory transfer. |
| Maintaining stability in dimensions for films | Maintain temperature and humidity per material guidelines and select backing materials that help maintain enough rigidity for die cutting. |
Foam and Cushioning Materials
| Issue | Expert Practice |
|---|---|
| Achieving consistent density across cuts | Use specialized blade angles when designing foam dies and control speed to minimize compression issues during the cutting process. |
| Cutting intricate shapes without tearing | Complex shapes often require multi-stage cutting processes, one cut for the initial separation and a second through cut. |
| Preventing compression set | As with other materials, provide adequate time for the materials to come up to the temperature and humidity of the storage area. Perform frequent checks for resilience and after-cut design tolerances. |
Rubbers and Elastomers
| Issue | Expert Practice |
|---|---|
| Avoiding edge deformation | Colvin-Friedman uses precision-ground dies and ensures that cutting pressure and speed properly match each type of elastomer. |
| Preventing sticking of cut parts to dies | Release agents are commonly used on cutting dies to ensure part separation while air ejection systems can also be used. |
| Maintaining tolerances in flexible materials | Similarly to edge deformation, maintaining consistent pressure and speed is crucial and can be done by implementing stabilizing materials and tracking cuts with quality control personnel. |
Abrasive Materials
| Issue | Expert Practice |
|---|---|
| Managing tool wear | Rely on hardened steel and carbide dies along with creating a replacement schedule. |
| Managing dust creation | Cutting stations should include dust collection systems and wet-cutting techniques can also help. |
| Achieving clean cuts without layer separation | Consider multi-layer cutting dies and, as always, optimize cutting pressure and speed. |
Or call Josh at (707) 769-4488
Best Practices for Die-Cut OHS Materials by Type
Since each of the materials used in creating occupational health and safety products has differences in tensile and compression strength, chemical and temperature resistance, and more, working with each one requires a different set of conditions. Below, we’ve listed what helps Colvin-Friedman maintain its standard of excellence and quality control.
Category Overview
| Category | Factor | Colvin Friedman Data |
|---|---|---|
| Experience | Years in OHS/Optical Manufacturing | 75 years in complex die-cutting like medical and electronics |
| Capabilities | Types of Die-Cutting Machines | Rotary, flatbed |
| Maximum Die Cutting Size | 16-inches rotary, 40 inches flatbed | |
| Materials | List of Optical-Grade Materials Handled | See table above |
| Quality Control | Inspection Methods Used (e.g., automated vision systems) | Vision systems, statistical controls, micrometers, calipers, various fixtures |
| Turnaround Time | Average Prototype Turnaround | 1-3 days |
| Average Production Turnaround | 3 weeks | |
| Capacity | Annual Production Capacity | Millions |
| Additional Services | Optical Design Assistance | Can provide design assistance to maximize quality control and die-cutting throughput |
| Assembly Services for OHS Products | Assembly service and inventory management system integration are available. | |
| Compliance | OSHA Standards Compliance | Complies with all OSHA standards |
| Financial Stability | Years in Business | 75 + |
Get Your OSHA Die Cutting Quote Today
Whether it’s face masks for personal protective equipment or gaskets to protect workers from noxious chemicals, Corvin-Friedman has been proudly producing the parts that make up crucial pieces of occupational safety and health equipment. If you’re looking for a quote for your OSHA die-cutting needs, please don’t hesitate to fill out the short form for a tailored response. You can also call our Vice President Josh Rodman at 707-769-4488 for answers to any questions you might have or to start the process.
Or call Josh at (707) 769-4488