Die Cutting for Pressure-Sensitive Adhesives
Colvin-Friedman brings 75+ years of experience in complex materials processing and we specialize in pressure-sensitive adhesives (PSAs). If not cut properly, PSAs may be susceptible to bleeding during cutting, inconsistent cut depth, material waste, and static buildup. Our team are professionals in cutting PSAs and mitigate these common issues. Below we explain our process for cutting PSAs to ensure our customers receive the highest quality component possible.
Expertise in Die-Cut Pressure Sensitive Adhesives
We are experts in die cutting PSAs, and generally specialize in the below component types:
- Medical/Surgical tapes
- Industrial labels
- Automotive interior component mounts
- Electronics/appliance components
- Packaging
We can aid in choosing a specific material for your component if one is not selected already. During our consultation process, we determine which PSA will work best for both your cost figures and desired functionality. Here are the common PSAs we utilize:
| PSA Type | Primary Industries | Common Applications | Strength Rating (1-5) |
|---|---|---|---|
| Acrylic-based PSA | Electronics, Automotive | Circuit board mounting, Panel bonding | 4 |
| Rubber-based PSA | Construction, Packaging | Insulation attachment, Carton sealing | 3 |
| Silicone-based PSA | Medical, Aerospace | Medical device assembly, High-temp gaskets | 5 |
| Hot melt PSA | Packaging, Product Assembly | Label application, Product assembly | 3 |
| Water-based PSA | Paper, Packaging | Label stock, Envelope sealing | 2 |
| Transfer Tape PSA | Various | Bonding dissimilar materials, Thin film applications | 4 |
| VHB (Very High Bond) | Construction, Transportation | Metal fabrication, Panel bonding | 5 |
| Removable PSA | Various | Temporary signage, Protective films | 1 |
| Foam PSA | Automotive, Construction | Gasketing, Sound dampening | 3 |
| Conductive PSA | Electronics | EMI/RFI shielding, Grounding applications | 3 |
Strength Rating Key: 1 - Very Low (easily removable) 2 - Low 3 - Medium 4 - High 5 - Very High (permanent bonding)
However, at Colvin-Friedman, we’ll show, rather than tell, what applications make the most sense. When it comes to pressure-sensitive adhesives, we’ve compared the following projects against each of the major types of cutting so that you can best understand whether die cutting makes sense for your project.
Or call Josh at (707) 769-4488
Projects Best Suited for Die Cutting vs. Other Cutting Methods
When it comes to pressure-sensitive adhesives, we’ve compared the following projects against each of the major types of cutting so that you can best understand whether die cutting makes sense for your project:
| Project/Application | Die Cutting | Laser Cutting | Waterjet Cutting | CNC Knife Cutting |
|---|---|---|---|---|
| High-volume production of adhesive labels | ✅ Ideal | ❌ Too slow | ❌ Too slow | ⚠️ Possible but slower |
| Thick foam gaskets | ✅ Ideal | ❌ Limited thickness | ✅ Possible but slow | ⚠️ Possible but slow |
| Intricate patterns on thin films | ✅ Good | ✅ Excellent | ❌ May damage material | ⚠️ Possible but less precise |
| Large format signage | ✅ Ideal for high volume | ⚠️ Good for low volume | ⚠️ Possible but slow | ✅ Good for low volume |
| Medical adhesive patches | ✅ Ideal | ⚠️ May affect adhesive | ❌ Not suitable | ⚠️ Possible but slower |
| Automotive interior trim | ✅ Ideal | ⚠️ Limited by material | ⚠️ Possible but slow | ⚠️ Possible but slower |
| Electronic component gaskets | ✅ Ideal | ⚠️ May affect properties | ✅ Good for prototypes | ⚠️ Possible but less precise |
| Adhesive-backed rubber seals | ✅ Ideal | ❌ May damage material | ⚠️ Possible but slow | ⚠️ Possible but less clean |
| Custom shape stickers | ✅ Ideal for high volume | ⚠️ Good for low volume | ❌ Not cost-effective | ⚠️ Good for low volume |
| Fabric/textile adhesive products | ✅ Ideal | ⚠️ May singe edges | ❌ May damage material | ✅ Good alternative |
| Printed circuit board (PCB) masks | ✅ Good | ✅ Excellent | ❌ Not suitable | ⚠️ Possible but less precise |
| Industrial strength tapes | ✅ Ideal | ❌ May affect adhesive | ⚠️ Possible but slow | ⚠️ Possible but less clean |
| Packaging inserts | ✅ Ideal for high volume | ⚠️ Good for prototypes | ❌ Too slow | ✅ Good for low volume |
| Adhesive-backed foam insulation | ✅ Ideal | ❌ Limited thickness | ⚠️ Possible but messy | ⚠️ Possible but slower |
| Reusable adhesive products | ✅ Ideal | ⚠️ May affect adhesive | ❌ May affect adhesive | ✅ Good alternative |
Legend:
- ✅ Ideal or Excellent: Best suited for this type of project
- ⚠️ Good or Possible: Can be used but may have limitations
- ❌ Not suitable: Generally not recommended for this type of project
Note: This table provides general guidance. Please contact Colvin Friedman for a quote on your project.
Or call Josh at (707) 769-4488
Best Practices for Die Cutting Pressure-Sensitive Adhesives
| Concern 1 |
| Adhesive Bleed During Cutting |
| Solution |
| To prevent adhesive bleed, maintain optimal die temperature and pressure. Use chill rolls or cooling systems to keep dies at the right temperature, typically between 60-70°F (15-21°C). Ensure die pressure is precisely calibrated - too much pressure can cause bleed, while too little results in incomplete cuts. |
| Concern 2 |
| Inconsistent Cut Depth on Liner |
| Solution |
| Achieving consistent cut depth is crucial for easy product removal without damaging the liner. We implement a multi-step approach: First, we design and use high-quality, precision-ground dies and regularly check for wear. We also regularly measure and record cut depths using a microscope or digital depth gauge. For multi-layer materials, experiment with different blade angles and pressures to find the optimal configuration for each specific PSA product. |
| Concern 3 |
| Material Waste and Inefficient Layouts |
| Solution |
| We minimize waste through strategic planning and nesting software to optimize material usage, arranging parts efficiently on the sheet. Even leftover pieces are scavenged for testing. |
| Concern 4 |
| Static Buildup During Cutting |
| Solution |
| Static electricity can cause misalignment and quality issues. We work to combat this by maintaining proper humidity levels in your production area, ideally between 45-55% relative humidity. We also perform regular testing with a static meter can help identify problem areas before they affect production. |
| Concern 5 |
| Ensuring Clean Edges and Preventing Tearing |
| Solution |
| Clean edges are crucial for both aesthetics and functionality. We start with selecting the dies that are appropriate for the PSA in question and perform regular inspections. Since cut speeds have to be weighed against production timelines, we both test and re-test to ensure that cuts are within tolerances and orders meet deadlines. |
Or call Josh at (707) 769-4488
The Colvin-Friedman Process for Quality Control
As with any manufacturing or production process, Colvin-Friedman spends more time ensuring details are ironed out (no pun intended) before a production run than during. We know that when it comes to die cutting, prior preparation will pay dividends, which is why actual production is step four of six in our process. When you work with us, we complete each of these steps:
| Initial Consultation |
| We begin by thoroughly discussing your project requirements, material specifications, and desired outcomes. Our experts will analyze your needs, offer suggestions for optimization, and provide initial cost estimates |
| Design and Prototyping |
| Our skilled team creates custom die designs tailored to your specific requirements. We use advanced CAD software to optimize material usage and ensure precision. Before moving to full production, we produce prototypes for your approval, allowing you to test the fit, form, and function of your die-cut adhesives. |
| Production Setup |
| Our experienced technicians configure our state-of-the-art die cutting equipment for your specific job. This includes setting up the custom dies, adjusting cutting pressures, and fine-tuning feed rates to achieve optimal results. We also conduct test runs to ensure everything is perfectly calibrated before beginning full production. |
| Quality Control |
| We are in constant contact with customers like you throughout the production process. This includes updates on regular inspections of die-cut parts, dimensional checks, and adhesive performance tests. Our quality assurance team uses advanced measurement tools and follows strict protocols to ensure every piece meets our high standards and your exact specifications. |
| Finishing, Packaging, and Delivery |
| Once done, our experienced team can easily work with most inventory management solutions on the market to ensure that we’re not just a supplier, but an integral part of your production system. |
Get Your Cost-Effective Quote for PSA Die-Cutting Today
As one of the leading American die-cutting experts, Colvin-Friedman has been committed to quality since being a part of the first electronics in the 1940s. Let us bring our attention to detail and commitment to quality to your project, ensuring that it meets your most exacting standards. Contact us today for a complimentary quote on whatever need you have for die cutting for pressure-sensitive adhesives.
Or call Josh at (707) 769-4488