Rotary Die Cutting Services
The #1 Rotary Die Cutting Provider
Since 1949 Colvin Friedman Has Rotary Die Die-Cut Millions of Units over Thousands of Designs
Colvin Friedman is one of the oldest and most experienced die-cutting companies in the United States. Since our founding we have been known for quality rotary die-cut products made to exceed our customers’ expectations. See the information below for our rotary die-cutting capabilities.
Our Rotary Die Cutting Capabilities/Specs
We can rotary die-cut products generally that fit within the following specifications. Depending on the design and material we can accommodate some products outside of the specifications. If your design does not work with the specifications we may recommend flatbed die cutting to accommodate.
| Category | Specification |
|---|---|
| Maximum Product Width | 16 inches we can slit down larger jumbos |
| Maximum Product Thickness | .015 inches however there is flexibility with different materials |
| Tolerance Level | Can get down to ±0.005 inches |
| Maximum Production Capacity | 40,000 units/hour (size dependent) |
| Average Lead Time | 3 weeks |
Specifically we offer the following services:
- 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
We Specialize in Thin Gauge Film and Sheet Plastics
If you are unsure whether your product or component can be rotary die cut consider contacting our Vice President Josh Rodman for more information. Also if you are changing your rotary die-cutting provider and wish to understand our pricing and see examples of our work product Josh will provide any needed information.
Or call Josh at (707) 769-4488
Materials Used
We can generally rotary die-cut any material for your products or components if they fit within the specifications listed above. Commonly we use these materials:
| Paper | Polyester Films |
| Foam | Rubber |
| Foil | Adhesives |
| Plastics | Fabric |
| Composites | Felt |
| Fiberglass | Silicone |
| Metallic Foil | Nonwovens |
Choosing a Material
If you are unsure which material to use for your product or component we will advise which will perform the best for your use case. There are a few important considerations when choosing a material to be rotary die cut:
- Material Properties: Various physical properties of the material such as the tensile strength, flexibility, durability, and resistance to heat, moisture, and chemicals should be considered to ensure the end product can withstand any mechanical stresses it may need to withstand.
- Material Form: All rotary die-cut materials must be able to maintain integrity and quality when stored and processed as a roll.
- Production Volume and Cost Efficiency: Rotary die cutting is used as a cost-effective solution for high-volume production. We assist in selecting materials to align with your overall budget and cost-per-unit target.
- End-Use Requirements: We examine the requirements of the finished product in categories including color, finish, conductivity, transparency, and insulation to ensure the chosen material will work well and in accordance with the end-use requirements.
We are happy to assist in material selection and provide a pros/cons list for each. Contact us below to begin the process of material selection and quoting.
Or call Josh at (707) 769-4488
Our Experience & Expertise
Our rotary die-cutting experience and expertise speak for themselves. We have partnered with companies all over the USA & the world to produce the following:
| Lenses and lens accessories | Gaskets |
| Seals | Decorative leather |
| Shims | Face shields |
Rotary Die Cutting: Is It Right for You?
Many people are unsure whether rotary die-cutting is the right solution for their product or component. Use the following checklist to determine if rotary die cutting will be a fit for your product.
- Material and Volume Requirements: For rotary die cutting to be a good fit the material you need to cut must be available in roll form. Additionally, the production should be a high volume as rotary die cutting is most efficient for larger runs as waste is minimized.
- Precision and Complexity of Cuts: If you need high precision and intricate cut patterns rotary die cutting may be a great fit for you. At Colvin Friedman we specialize in complex shapes and hyper-accurate tolerances.
- Speed and Cost Efficiency: If you prioritize fast turnaround times and cost efficiency in large-scale production rotary die cutting is generally faster than other die-cutting techniques like flatbed die cutting.
If your product steps outside of these you may consider flatbed die cutting. We also offer flatbed die cutting and can help you choose between the two.
Rotary Die Cutting vs 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 |
If you are unsure which option will work best for your product/component and your desired production run size we are happy to assist. Reach out below for a free quote along with guidance on choosing a type of die cutting.
Or call Josh at (707) 769-4488
Rotary Die Cutting Best Practices
| Category | Best Practices | Description |
|---|---|---|
| Planning and Pre-Production | High Quality Materials | Source best materials available for premium components |
| Testing and Adjustments | Test and adjust die design if necessary for peak quality | |
| CAD | Utilize Computer Assisted Design (CAD) software to precisely design die | |
| Optimize Die Geometry | Design for optimal bevel angles, to avoid material build up and reach peak efficiency | |
| Die Construction | Experienced Toolers | Guarantee Top Quality Dies are created by experts |
| Quality Steel for Dies | Dies are created with high grade steel for clean cuts and maximum durability | |
| Milling and Heat Treatment | Help ensure sharp and durable edges for the die | |
| Produce Test Products | Initial products are evaluated to ensure die’s quality before production | |
| Project Execution | Precise Calibrations | Machines are set to client’s specific requirements |
| Sample Tests | Integrated to ensure dimensions and tolerances remain up to standard throughout production | |
| Optimized Systems | Use SCADA and PLC systems to enhance and automate the cutting process | |
| Material Guides and Rollers | Keep material fed smoothly through machine, avoiding friction and drag |
Our Rotary Die Cutting Process
At the core of our process is quality. We ensure each product from the first to the last is within your specifications and will work perfectly for your use case. Below we’ve included a diagram explaining our process to ensure all products are made to your specifications and with the utmost quality.
Stage One - Consultation and Design
During the initial consultation, we examine your product specifications and determine important specifications such as the type of die cutting that should be used, the material, finishing requirements, and tolerance requirements. If a prototype is needed we will aid in creating it for you. Once the final design is settled on, we create several test products to ensure the design is perfect before heading into production.
Stage Two - Testing and Refinement
Before the production process, we perform tolerance level tests, overall dimension tests, and fit and function tests to test the quality of the design. If the product does not pass the tests with flying colors, we will assist in design refinement to ensure a smoother manufacturing process. At this stage, the customer may perform their own tests and provide feedback. We can create multiple iterations of the product to enhance quality and functionality.
Stage Three - Production and Scaling
Before production, the product is put through our full QMS to ensure the product will work perfectly for the customer once produced. We work quickly to get our machines equipped to produce the order. A small-scale production run is done as a final fail-safe before the full production run. Any adjustments can be made before the full production run.
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