Die Cut Gaskets & Pads, Gasket Die Cutting

Die Cut PoronStockwell Elastomerics is a leading manufacturer of die cut gaskets and pads. Stockwell Elastomerics uses gasket die cutting with a variety of elastomers, especially silicone rubber, and provide customers with these and other benefits:

  • Fast and efficient custom gasket cutting
  • Low-cost steel rule die cutting available
  • Machined solid steel dies for more complex and tolerance sensitive parts
  • CNC die cutting with optimizing software for maximum material yields
  • Generous die footprint for larger parts

Die Cut Gasket Applications

Stockwell Elastomerics specializes in die cutting custom gaskets for many different industries and applications. This is a partial list of some of the die cut gaskets and pads that can be provided.

Best Die Cutting Methods

There are several processes or combination of processes that can be utilized to produce custom die cut gaskets and pads.

  • High-speed flatbed die cutting and kiss cutting
  • Continuous feed die cutting with CNC technology
  • Beam presses with manual and traveling heads
  • Knife slitting

The best gasket fabrication method will vary depending on tolerances, quantities, and the materials being cut. Stockwell Elastomerics will work with engineers to help design for the best converting method, reducing cost and improving handling. In addition to die cutting, Stockwell Elastomerics offers flash cutting, waterjet cutting, and custom molding.

Design for Manufacturing (DFM) Assistance

Stockwell Elastomerics works closely with its customers to help design parts and use the best converting method. The design for manufacturability (DFM) review that Applications Engineers perform helps to reduce manufacturing costs and improve part handling. Slight design modifications up front can save thousands of dollars in production costs later.

High-Speed Flatbed Die Cutting and Kiss Cutting

Stockwell Elastomerics uses automated flatbed die cutters for relatively small, thin die cut gaskets that have mid-level volumes ranging from 100,000 to 500,000 parts per year. Die cut gasket part sizes generally range in size from 0.25″ square or round to 12″ square or round. Flatbed die cutters are also capable of “kiss cutting” gaskets or pads that have adhesive on one side. Kiss cutting refers to how the die, or tool, cuts through the gasket material and just into, but not completely through, the adhesive liner. Kiss cut gaskets are then wound on a roll for shipment.

  • Advantages: High-speed gasket die cutting is the fastest and most effective way to cut thin, simple parts. It also offers kiss cutting capabilities.
  • Limitations: Automated flatbed die cutters can’t cut large parts, or parts with adhesives on two sides. With thicker materials, edges may be deformed.

Continuous Feed Die Cutting with CNC Technology

Stockwell Elastomerics’ CNC equipment is used to die cut mid-to-large-sized gaskets in mid-level volumes ranging from 100,000 to 500,000 parts per year. Optimizing software, a continuous belt feed and an accelerated hit rate help make this type of die cutting even more efficient.

  • Advantages: Fast and cost-effective for mid-to-large-sized gaskets in mid-level volumes. The continuous feed and other features help speed production.
  • Limitations: Longer setup times, edge deformity on thicker materials, and some material limitations.

Beam Pressed with Manual and Traveling Head

Stockwell Elastomerics also die cuts parts on manual and traveling head beam presses. Typically, these die cut parts are similar in size to those that are cut with the CNC unit. The difference, however, is that the manual and traveling head beam presses are used with lower volumes.

  • Advantages: Minimal setup time, cost effective for low volume runs of large die cut gaskets.
  • Limitations: Manual feed, edge deformity on thicker materials, some material limitations.

Knife Slitting

Knife slitting is used with gasket tapes and strip rolls. A master sheet is rolled onto a 3″ diameter core and presented to the slitter, where it is cut into smaller rolls. Often, this roll is then sent to a die cutting station for a straight blade cut on a specific progression – the resulting part is a rectangle or square. This method of slitting a roll and then using a straight blade cut is called progression cutting.

Die Cutting Alternatives: Flash Cutting and Waterjet Cutting

For prototyping and lower production volumes, Stockwell Elastomerics offers flash cutting and waterjet cutting services. Flash cutting is a die-less, automated process that uses reciprocating knives and CNC technology. Waterjet cutting is a tool-less process that uses a highly pressurized stream of water instead. Flash cutting and waterjet cutting are ideal for quick-turn, iterative prototypes and low-to-medium volumes of production-quality parts with intricate features. With its flash cutter and four water jet cutters, Stockwell Elastomerics can help customers meet critically short deadlines.

  • Advantages: Accurate cuts and intricate parts without waiting for or paying for dies
  • Limitations: Longer cycle times and the least cost-effective way to cut simple parts in higher volumes

Considerations for Cutting Gaskets and Pads

  • Geometry – Parts with thin walls (less than 0.1″) may not die cut well, and may require flash cutting or waterjet cutting.
  • Material Type – Certain materials are susceptible to edge deformation during die cutting. Depending on your application, some degree of concavity may or may not be acceptable.
  • Material Thickness – In conjunction with material density, thickness plays a significant role in how well a material can be cut, and if it can be die cut at all.
  • Tolerances – The part tolerances for softer materials like elastomers need to be looser than with sheet metal. Parts that require tight tolerances may require solid steel tooling. Waterjet cutting is also an alternative.
  • Volume – Large volumes of parts that are cut with CNC equipment provide the greatest cost savings.
  • Packing and Shipping Method – Most manufacturing cells prefer parts that are packed in a specific fashion. Examples include parts that are on a roll, cut through, or on a strip. No matter which cutting method is chosen, the packing method should be considered before finalizing the design to provide a significant cost savings during manufacturing.

Contact Stockwell Elastomerics for Custom Die Cut Gaskets & Pads

Contact Us for further assistance with custom gasket die cutting, including high speed die cutting, kiss cutting, continuous feed CNC, beam press, and knife slitting to make custom die cut gaskets and custom die cut pads.