Laser Cutting Has Evolved: Here Are its Advantages Over Die-Cutting
When it comes to using 3M™ VHB™ foam tape, precision is paramount.
For decades, the go-to method to convert VHB™ and other foam tapes was die-cutting. In terms of overall efficiency and consistent quality, die-cutting came closest to hitting these targets. However, with this method, achieving extremely close tolerances with these thicker tapes has been difficult at best.
Today, however, thanks to advances in laser-cutting technology, project designers can now achieve the most intricate dimensions and the tightest tolerances from VHB™ tape. That offers more freedom of design without sacrificing quality or raising the overall costs of custom gaskets.
In the following, we’ll unpack the differences between the two cutting methods. Then, we’ll discuss how laser cutting can help you achieve the best results.
Die-Cutting vs. Laser Cutting: Understanding The Fundamentals
Which is best for cutting foam tapas, die-cutting or laser cutting?
Short answer: It depends on what’s more critical — product quality or production efficiency.
Traditional die-cutting presses the metal die into the material to cut out the desired shapes. A custom die results in higher upfront costs and increases lead time initially. Once accomplished, die cutting often produces the highest volume of identical shapes in the least amount of time at a relatively low cost per unit.
However, if intricate shapes and very close tolerances are top priority, laser cutting may be the better option.
Laser cutting uses a high-powered beam of heat guided by computer software to cut materials with exceptional precision. Because there is no need for dies, laser cutting was always a great option for prototyping and small batch production runs.
In recent years, the technology behind laser cutting technology has advanced significantly. Namely, it’s faster and produces higher quality results, making it a more viable option even for thicker foam materials like VHB™ tape.
Higher Tolerance, Greater Complexity
One of the most compelling advantages of laser cutting over die-cutting is its ability to cut very close tolerance parts, even from thicker foam materials like VHB™ tape. Here’s a comparison of their tolerance ranges:
- Die-cutting +/- .030 inches
- Laser cutting: +/- .005 inches
With this level of precision, laser cutting opens new possibilities for product design. Would you like to achieve complex geometries or more intricate features? Despite the relative thickness of VHB™ tape, these are easily achieved with laser cutting.
More Parts, Less Waste, More Savings
Another advantage of laser cutting is it can also slash material use, thanks to the use of computer-aided technology.
Die-cutting can leave behind more matrix because of the nature of the manufacturing process. As the metal die slices through the material, it’s important to leave room for material displacement.
However, laser-cutting’s precision and its computing capabilities can nest parts closely together. The result is more parts per yard and a significant reduction in material waste. You’ll reduce material costs while being a little gentler on the environment.
Rapid Turnaround and Prototyping
A key advantage of laser cutting is it offers greater range of design flexibility over using metal dies. The beam is guided by computer software, meaning all that’s needed is a CAD file. Any last-minute design changes can be adapted immediately with a simple file update. Because laser cutting requires no custom tooling, it’s well-suited for quick-turn prototyping and certain rush orders.
Greater Assembly Efficiency With Kiss-Cutting
Laser cutting can also perform kiss cuts — a technique where the laser cuts through the top layer of material and adhesive, leaving the liner intact. This is great for applications where parts need to be easily handled and assembled, as it allows for quicker assembly times and reduces the risk of damaging the adhesive during handling.
Unlock New Design Potential With Laser Cutting
At SRP, we’re fully equipped to help you innovate. When it comes to high-performance gaskets and seals, our solutions will raise your standards in design and function. Contact us today to discuss your project.