Thin, non-metallic gaskets are often produced by die cutting. It’s an economical process that’s especially useful for making gasket kits. However, as with every manufacturing process, there are some limitations. This blog will describe what die cutting involves, what it’s capable of, and its relevance to kits.
Steel Rule Die Cutting
Die cutting involves pressing a sharp steel blade down into the material. This blade is bent into the profile of the gasket needed and secured in a plywood or phenolic board. The board is then mounted to the upper surface of a press, which pushes it into sheet material placed underneath.
Die Cutting Process Capabilities
Maximum gasket size and thickness are determined by the press. Our 75 ton presses can die cut parts up to 36” x 62” and up to 1” thick. (Thickness depends on the material being cut and the profile length.)
Cutting dies are inexpensive and can be nested to improve material utilization. Controlling the depth of cut enables “kiss” cutting, where the blade only goes part way through the material, or stops at the backing layer.
Advantages of Die Cutting
A major strength of this process is the ability to make gasket kits. This is done by nesting multiple blades on a board, which ensures the required quantities of each gasket are made.
In addition, by kiss cutting the sheet, the gasket kit is kept together. This simplifies handling and storage.
Die Cutting Limitations
This is a process that needs part-specific special tooling. We hold a substantial inventory of dies, but a new tool will be needed for a custom shape. In addition, the press needs a limited amount of setup before running an order.
Together, these points mean die cutting is best for medium quantity orders. For small quantities we recommend flash or waterjet cutting instead.
Our Custom Die Cutting Services
If we don’t have a die for your particular gasket shape we will be happy to make one. To ensure accuracy, we can reverse engineer existing gaskets to produce a custom die for your needs. Contact us for a quote.
