Die Cutting

Die-cutting is one of our most important processes and an area of our greatest advances. Our in-house conversation facility includes high-speed rotary die-cutting equipment with innovative capabilities and flatbed presses enabling unlimited flexibility to convert nearly all our advanced materials into precision components.

Ultra Fast Conversion

Die-Cutting

Die Cutting 3M Product

Advanced manufacturing

Our advanced manufacturing and conversion facility enable the production of a vast range of die-cut components using customised liner configurations and presentation styles.

  • Ultra-fast processing speeds up to 150 metres per min and up to 1.5 million parts per hour
  • 100 tonne, 2m x 1.5m cutting bed, multi-reel fed
  • Ability to configure complex multi-layer components using a customised presentation and format to improve productivity during product assembly
  • Automated pick and place for packing and component placement
  • Advanced robotics for assembly and automated packing.

By looking beyond the initial drawings, we carefully analyse and consider all aspects of the application focusing on how we can most effectively configure the format to improve efficiency and reduce costs.

Die Cutting

Parameters

  • Slitting Rewinding

    Rotary Die Cutting

    Part size up to 500m wide x 1200mm length

    Running speed up to 150 m/min +

    Cutting tolerance up to +/- 50μ

  • Die Cutting

    Flat Bed Die Cutting

    Part size up to 2000m wide x 1500mm length

    Running speed up to 120 m/min +

    Cutting tolerance up to +/- 250μ

Surface Modification

For LSE Substrates

Inline Corona Treatment

Surface treatments modify the surface of low surface energy (LSE) substrates during the die cutting process to allow application of pressure sensitive adhesive (PSA) to materials which have an inherent LSE that were previously incompatible with PSA.

1. Increases Surface Energy Dyne

Inline Corona Treatment increases the surface energy dyne level of LSE materials such as foams, composites, acrylics, films and PP by up to 3 times.

2. Enables Application of PSA

This highly effective treatment allows the lamination of conventional PSA’s onto LSE substrates that would otherwise not be available, without any reduction in manufacturing speeds, eliminating the need for high cost chemical surface preparation and specialist adhesives.

3. Broadens Range of Materials

Using this surface modification during the die cutting process and prior to bonding, coating, laminating or sealing broadens the range of adhesives and substrates that are compatible with LSE materials previously unsuitable for the same application.

How Corona Treatment Works 

  • The treatment creates a high voltage electrical discharge known as Corona Discharge
  • High energy Corona Discharge effectively severs molecular bonds on the surface of the material and attach to free radicals within the Corona Discharge
  • This surface modification results in enhanced surface energy and increased adhesion of various materials

Cleaner Materials

Particularly important during the manufacture of medical components, devices and equipment, enabling Material Scientists to utilise cleaner materials and helping to replace substrates such as vinyl and latex. With greater design flexibility, we are able to support our clients in the development of tomorrows technology.