Flatbed Die Cutting Services

Mercer Gasket & Shim is equipped with new, state-of-the-art flat die cutting equipment. We can assist with mid to high volume mass production runs.  Our capabilities include making material recommendations, CAD design, engineering support, and computerized reverse engineering.  We have developed a reputation for delivering high-quality solutions with quick turnaround times. As an ISO 9001:2015 certified company, we serve our customers with products and services that undergo strict quality control management.

In-House Flatbed Diecutting Specifications:

To learn more about how we can serve you, contact Mercer or request a quote.

If you want to learn more about flatbed die cutting keep reading:

When should I consider using flatbed die cutting?

Flatbed die cutting is a manufacturing process used to cut, shape, and create various flat materials, such as paper, cardboard, plastic, foam, and other non-metallic substances. It involves the use of a flatbed die cutting machine, which utilizes a custom-made die to cut the material into specific shapes or patterns.

Here’s a brief overview of the flatbed die cutting process:

1. Die Design: A die is a specialized tool made from metal that has a sharp cutting edge. It is designed based on the specific shape or pattern required for the material.
2. Material Placement: The material to be cut is placed on a flat surface, typically a bed or table, within the die cutting machine.
3. Die Cutting: The die is pressed onto the material with significant force, cutting through the material and creating the desired shape.
4. Removal of Waste: The excess material, known as waste or scrap, is removed, leaving behind the cut pieces.

Flatbed die cutting is suitable for various applications, and it is often preferred under the following conditions:

1. Custom Shapes and Designs: When precise and custom shapes or designs are needed, flatbed die cutting is an excellent choice. The die can be created to match specific requirements accurately.
2. Medium to High Volume Production: Flatbed die cutting is efficient for medium to high volume production runs. It allows for rapid and consistent cutting of materials, making it cost-effective for larger quantities.
3. Multiple Layers or Thick Materials: It is well-suited for cutting multiple layers of material or thicker substrates. The force applied during the die cutting process ensures clean and accurate cuts even through thicker materials.
4. Tight Tolerances: Flatbed die cutting provides high precision and tight tolerances, making it suitable for applications where accuracy is crucial.
5. Various Materials: It can be used with a wide range of materials, including paper, cardboard, rubber, plastics, and more. This versatility makes it a popular choice for diverse industries.
6. Prototyping and Short Runs: Flatbed die cutting is suitable for prototyping and short production runs, providing a quick and cost-effective solution for small batches.

Here are five Industries where flatbed die cutting is considered an ideal cutting process:

1. Packaging Industry, Die-Cut boxes: Flatbed die cutting is commonly used in the packaging industry to create precisely cut and scored cardboard or paperboard boxes. This process is efficient for mass production of custom-shaped packaging for various products.
2. Label Manufacturing: Flatbed die cutting is widely used for creating custom-shaped labels with precision and efficiency. It allows for intricate shapes and sizes, making it ideal for producing labels for various industries, including food and beverage, cosmetics, and pharmaceuticals.
3. Automotive Industry: In the automotive industry, flatbed die cutting is employed to manufacture gaskets and seals for engines and other components. The process allows for the efficient production of high-precision, custom-shaped gaskets and seals from materials like rubber and foam.
4. Medical Industry: Flatbed die cutting is used in the production of medical components such as adhesives, foams, and films. It enables the manufacturing of precise and intricate parts used in medical devices, ensuring a high level of quality and consistency.
5. Textile Industry: In the textile industry, flatbed die cutting is utilized for cutting fabric pieces with precision. This is especially useful for cutting intricate patterns and designs in textiles used for apparel, home furnishings, and other textile products.

Flatbed die cutting is chosen for these applications because it offers high precision, repeatability, and efficiency in handling a wide range of materials. Additionally, the process is suitable for both small-scale and large-scale production runs, making it a versatile solution for various industries.

Contact us for a quote or to learn more about Mercer’s flatbed die cutting!

MAIN FEATURES & BENEFITS

Here are the primary characteristics and advantages of flatbed die cutting:

• High Precision: Flatbed Die-Cutting Machines Can Produce Clean Cuts On Both Thin And Thick Materials.
• Cost Savings: Since Flatbed Die-Cutting Is An Automated Process, There Are Lower Labor And Tooling Costs, Which Helps Manufacturers And Customers Save Money. Multiple Parts Can Be Grouped Into A Single Piece Of Stock, Which Also Reduces Trimmings And Material Waste.
• Fast Turnarounds: Even For High-Volume Projects, Flatbed Die Cutting Can Meet Tight Deadlines.
• High Efficiency: Thanks To Automation, Flatbeds Minimize Manual Labor And Improve Overall Production Efficiency. This Method Also Produces No Unproductive Motion Because It Utilizes Constant Rotation.

COMMON APPLICATIONS OF FLATBED DIE CUTTING

Flatbed die-cutting operations can create a variety of components, such as gaskets, packaging, bumpers, dampeners, labels, printed products, and more.

1) Through-Cutting

As you might imagine, die cutters are often used simply for cutting. They can cut through numerous materials, including paper, metal, and wood, to make various shapes and sizes. Whether you’re using them for your products or their packaging, through-cutting is the most basic function these machines offer.

2) Kiss-Cutting

Kiss-cutting means cutting partially through a material. This can be helpful for creating different designs and products as well as making materials easier to fold at specific points. Kiss-cutting is often used for cutting out stickers while leaving their backing intact.

3) Broaching

You could say that broaching is the opposite of kiss-cutting. Whereas kiss-cutting creates a shallow cut in a material, broaching uses specialized teeth and brute strength to cut through incredibly thick materials.

4) Creasing

In the process of creasing, die cutters imprint fold lines in materials. This makes them easier to fold when needed and helps prevent tearing, cracking, and other types of damage to the material being used.

5) Cutting By Color

Die cutters can also be programmed to cut only specific colors in materials. They’ll first seek out the preset colors and trace them. Then, they’ll go back over the colors with their cutting tools. It doesn’t matter how intricate the patterns are or how intertwined the designated colors maybe with other hues. Die cutters can easily pinpoint a single color and cut along its borders.

6) Engraving

Engraving is another task die-cutting machines are capable of performing. They can engrave designs into all types of materials, including cardboard, metal, and foam. They can create ornate engraved patterns or something as simple as a person’s initials.

7) Embossing

Whereas engraving creates depressed designs in materials, embossing creates raised patterns and designs. You can use die cutters to emboss designs into materials for an impressive decorative or 3-D effect.

8) Perforating

Perforating places rows of lines or holes in materials.

Die Cutting Offering Endless Possibilities

Those are only a few of the actions die-cutting machines can carry out. You can set up these machines to perform multiple tasks as well, combining several functions of your manufacturing process. Die cutters bring to the table an array of possibilities no matter what materials you’re working with or which end products you have in mind.

Contact Mercer Gasket for Flatbed die Cutting Services.