Rotary Die Cutting is a method of cutting bespoke shapes of pad or gaskets from a roll of flexible adhesive coated materials.
The material is unrolled and passes through two rollers and one roller has the imprint of the part you are looking to convert magnetically held in place.
With the Rotary Die Cutting process, a primary roller has a raised blade that impinges on a secondary roller with high accuracy, thereby cutting the part shape required.
Once your shape has been through the rotary die cutter, the remaining scrap material is removed and just your parts are left and re-rolled.
A counter set on the side of the rotary die cutter counts the parts as the roll is cut. It is a very fast and accurate method of converting.
This manufacturing method can be used to convert many styles of material such as EMI, Thermal pads, Adhesive tapes, and films.
Rotary die cutting enables us to cut single-sided and double-sided adhesive materials.
A Rotary Die Cutting tool is a tool that produces the imprint of the part but applied to a cylinder. The cylinder with its imprint tool and another drum set to a specific distance. The material to be cut is then passed between the 2 roller cylinders.
The parts are cut to size and the scrap removed. The parts are re-rolled ready for delivery. Parts required to be supplied on a roll require a tool to be manufactured and therefore a 24hr service for this technique is not possible.
Customers requesting parts on a roll should in the first instance make contact by email or make the request in the notes when placing an order.
We will then review this and advise if it is the best method of production for your order and if the material suits this method. (for instance, we cannot roll cut sheets of material; they have to be rolls of material to begin with).
Materials direct has the ability to manufacture 100,000’s of parts per hour and so this technique is usually reserved for the higher volume requirements. A rotary die cutting tool is required to be manufactured and therefore a 24hr service for this technique is not possible.
In keeping with our commitment of delivering No tooling charge, we only offer this service when our customer’s order is of a high volume to suit our manufacturing process. This ensures that we get full use of this tool over time.
Materials Direct is approaching this market in a way that is easy to order and specify in Electronics across all industries. Customers who need a certain brand of material that does not appear on the site can apply for us to add this stock to the site’s portfolio based on potential usage.
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The main problem for design engineers and purchasing has been until now the quick supply of parts as often the custom pad is one of the last items to be specified in the design of an Electronic assembly.
Materials Direct not only provides an instant quote but gives the buyer the offer of uploading their custom design for it to be manufactured within 24hours if the material is in stock.
When cutting a double-sided adhesive we cut through the top liner and the material but leave the part on the bottom liner.
The customer then takes the part with its liner attached off of the roll and applies it to the assembly and the last stage is to remove the top liner exposing the top layer of adhesive.
The speed at which we can produce parts makes Rotary Die Cutting the most suitable method for us if the business demands it.
The part sizes we manufacture in this way are a maximum of 290mm x 200mm (max roll width 300mm) but the majority of parts tend to be small but high volume so we would step and repeat the design across the roll.
The advantage of supplying parts on a roll is very efficient as parts are peeled directly from the roll like a sticky label.
The parts are also very clean as they are not exposed to the environment until they are unrolled.
All of our rotary Die cutting services are carried out by experienced and trained professionals who have a high understanding of how the machines work and how they should be used.
Materials Direct will also only source materials from trusted Brands.
Very fast reply, very good order following and delivery in 24H. to recap a verry good experience with Materials Direct for a verry urgent need. I recommend a lot.
'Having the ability to be supplied with precision cut materials for prototypes within 2 days has been excellent!’
'We have the need for small to medium batch sizes of various technical materials and Materials Direct have been highly responsive to our urgent needs'
‘We have had to change our designs in the development stages three times. Materials Direct did not charge for these changes as the sizes stayed the same. Excellent!’
‘Precision and high quality of parts received have been consistently to a high standard.’
'Buying online with Materials Direct has proven to be more efficient in time and deliveries, especially when scheduling future orders.’
Each sector has its own unique requirements and specifications. Materials Direct works to ensure that each sector we supply to, receives the highest quality and best-performing products in relation to their industry and specific need.
The Aerospace industry demands the highest performing, most reliable technical materials to protect their electronic assemblies.
Automotive applications range from Engine management systems to motor drive controllers and custom-made gaskets and pads.
Industrial electronics are robust, have long lifetimes, are cost-sensitive, and suitable for use within difficult environments.
Sufficient thermal management in LED lighting can preserve longevity, increase reliability and optimise performance.
Materials used in military applications need to be of the highest quality and performance, often very rugged to very exacting standards.
Coupling discreet heat-generating semiconductors to heatsinks remains commonplace in power supply assemblies.