What does a custom foam gasket cost? 

Looking for a competitive edge? Getting strategic with cost savings is a reliable path. Because in the realms of manufacturing and product development, the unexpected can happen at any time. Prices fluctuate, shipments get delayed, and industry requirements are continuously changing.  

At SRP,  we’ve been in the business of manufacturing custom gaskets since 1951. With our decades of experience, we have a few time-tested strategies to help you gain control over gasket costs.  

What has the biggest impact on gasket cost? 

Looking for ways to make custom foam gaskets more cost-efficient? These three areas have the largest impact on your per-unit costs. 

1. Chosen gasket material. 
2. Production volume. 
3. Turnaround time. 

The following will show how these areas impact the cost of custom gaskets and how you can exert some control to get the greatest value. 

1. Materials

More than any other factor, the type of foam gasket material and pressure sensitive adhesive will have the greatest impact on your per unit cost. But there are some areas where it’s possible to exert more control. 

And this is where we at SRP can help you. 

Material analysis for quality  

Quality matters when choosing foam materials and gasket tape. 

Selecting based on price alone can result in premature gasket failure, leading to higher costs in the long run (along with a hit to customer goodwill). And yet, there’s no need to pay premium prices for premium materials when the application only requires a standard material like an industrial EPDM or Neoprene, rather than a spec grade. 

At SRP,  our focus is value and quality. Our experts can help you identify a material that achieves the performance you’re looking for. 

Because at the end of the day, people want the best result, not necessarily the cheapest product. 

Maximize your material yields 

At SRP, our processes are designed to help you get the most yields per area of material. We use tools like computer-aided software with part nesting capabilities, so we can get the maximum number of parts per area of material. 

Proactively prevent errors  

Errors in die cutting can be costly. Choosing the right cutting method for a given foam material will prevent rework and ensure consistency and quality.

Our team is one of the most experienced in the business. That speaks to the strength of our team. Many of our people have been with us their entire careers. With that level of experience working for you, your projects will have a higher success rate and better outcomes. 

Tolerance in soft materials 

When you’re looking for a precision fit, it makes sense to ask for a close tolerance part, right? Depends on the material. For rigid materials like metals and hard polymers, a close tolerance cut makes sense. 

However, when die-cutting soft, flexible materials, variation is inevitable. Typically, die-cut foams can accommodate a wider tolerance range than rigid materials and still function exactly how they’re designed. 

Otherwise, if you don’t account for slight variances in die-cutting soft materials, a high percentage of perfectly good gaskets will end up getting binned. 

Not sure how to calculate the best tolerance for your part? No problem! The experts at SRP can pinpoint the most cost-efficient means to create your gasket. 

2. Production Volume 

In manufacturing, every moment counts. That’s why we focus on keeping production time productive. 

Die-cutting method is often tied into that. Some methods, like laser cutting and water jet cutting score high on precision. But unlike traditional die-cutting methods that can stamp shapes out of material, it takes longer to make a part. If you have a large volume, that can lead to cost increase. 

To get a deeper understanding of how production impacts gasket cost, read our blog, Die-Cutting Methods for Custom Gaskets: Understanding The Pros and Cons. 

3. Turnaround Time 

A reliable cost control method is managing your production timeline. It pays to leave yourself a cushion. Otherwise, when deadlines get tight, you may incur extra costs to expedite production or express ship an out-of-stock material. 

Fortunately, SRP has a precise system with cost estimates and a quick turnaround time. That gives the ability to offer lean lead times for many custom gasket orders, especially when they feature in-stock, readily available materials. 

We pride ourselves on having the agility to accommodate special requests and deadlines. But at the end of the day, being proactive with deadlines will be a cost advantage for you. 

Maximize Quality and Efficiency With SRP 

SRP has the latest equipment and manufacturing expertise to achieve the best production efficiency and gasket quality for your order. Contact us today to discuss your latest project. 

Custom die-cut gaskets solve a host of problems. As foams, sheet rubber and adhesives become more advanced, the possibilities expand. Gaskets make our world increasingly quieter, better connected, more portable and better designed.  

Foam Expo is an opportune time for engineers and product designers to collect samples of the best materials on the market. But the next step in the process is finding a converter to finish the foam, die-cutting it into functional gaskets. That’s where SRP comes in. 

We’re in the business of problem solving, identifying the best materials that enhance your product and die-cutting them with precision. 

Want proof? Here’s a sampling of our successes. 

Restoring Safety and Function to Gas Sensing Devices 

A manufacturer of a gas-sensing device was having serious issues with product design. The filter gasket was a critical component, sealing out dust and moisture and other contaminants. 

However, the closed cell foam gasket it was using had a high failure rate due to impact and compression set. 

Through our preferred partnership with Rogers, we quickly identified a substitute for the gasket: Rogers PORON® 92 formulation. Its superior resilience offered enhanced sealing ability — and better protection of the health and safety of the end users. 

Read our case study: Identifying the Right Gasket Material to Restore Function to a Gas Detector

3M VHB Tape Shortens Production 

Metal fasteners are effective but aren’t without their downsides. Installation is messy and labor intensive. Over time, even a slight loosening causes irritating rattles and vibration for the end user. 

Our automotive client was seeking a quieter, streamlined alternative to metal parts. Thanks to our deep expertise in 3M VHB tape, we had the best formulation at our fingertips. 

This pressure sensitive adhesive has a powerful bonding strength that’s easily applied — helping our customer save significant cost through production efficiency. 

Read our case study: 3M VHB tape for Automotive Application

Protection and Longevity For Fire Safety Devices 

A manufacturer of fire safety devices needed something long-lasting but protective. Smoke detectors require gaskets that resist flame and heat along with a compression set. 

Our solution: BISCO Silicone HT-800 foam. It can take a constant temperature of 392 degrees Fahrenheit and constant pressure to maintain a protective seal for the life of the device. When lives are on the line, performance is paramount. 

Read our case study: High Temperature Gaskets For a High Temperature Application

Cost Savings and Rugged Protection 

When we can save our customers money — without sacrificing performance — we  will not hesitate to point out the less expensive option. 

A great example of that is this cabinet for a telecommunications application. All it needed for a seal was a simple, inexpensive closed cell sponge rubber that’s been on the market for years. 

Sure, there are advanced foam rubbers that cost more with impressive sounding properties. But if there’s no advantage, we’d never sell you the more expensive material. That’s our promise.  

Read our case study: Sealing Gasket for a Telecommunications Cabinet 

Here’s a second example of how we saved customers money: Switching to a More Cost Effective Material

SRP: Enhance Performance at the Best Value 

Some projects call from the latest and greatest material. Others need only a simple rubber that’s been around for decades. To us, what matters most is creating the best performance at the best value. Foam Expo is an opportune time to discuss smart solutions for your application. Fill out this form and let us know you want to talk to one our experts during Foam Expo.

Die-cut gaskets hold the world together. That’s why when you’re designing a custom gasket, you select the elastomers and adhesives with utmost consideration, or the consequences can be costly. Equally important to gasket design is selecting the right machining method to manufacture them, which is why custom gasket manufacturers invest in multiple die-cutting technologies. 

Die cutting and how it impacts cost and quality of your custom gasket 

Depending on your gasket and how they need to perform, each die cutting method has advantages and drawbacks. When choosing the best method, custom gasket manufacturers will weigh things like material properties, project volumes, tolerance requirements and output per volume. They also factor your top priorities, cost or quality. 

If you want to understand how and why your custom converter chooses a specific die cut to fabricate your gasket and its impact on project costs, this comparison guide provides a great starting point. 

Steel Rule Die Cutting

Steel-rule die cutting is by far the most common method for manufacturing gaskets. Like a mechanized cookie cutter, it presses a steel rule die directly into the material to cut the shape.  

Advantages 

• Cost-efficient for large production runs. 
• Higher throughput with the ability to nest additional rule within the steel rule to achieve multiple cuts in a single pass. 
• Consistent clean cuts and smooth edges. 
• Low upfront costs for custom-shaped dies. 

Consideration 

• May cause some material displacement. 

Rotary Die Cutting

Custom dies are fitted on a cylindrical anvil and rolled on the flat material to remove shapes and leave perforations in the material.  

Advantages 

• Exceptional throughput,ideal for high-volume or repeat projects. 
• Achieves consistently accurate kiss-cuts well as perforations. 
• Optimal method for producing pressure sensitive adhesive-backed components on a liner. 

Considerations 

• Greater lead time and expense for sourcing custom-shaped metal dies. 
• Less cost-efficient for small-volume or single production runs. 

Reciprocating Knife Cutting

A blade guided by a robotic router cuts precise shapes from sheets of foam and other flat materials. 

Advantages 

• Eliminates the need for custom dies for shorter lead times and no tooling costs. All that’s needed is an updated CAD file.
• A true multi-purpose tool with the highest variety of cuts at various depths, all within the same production run. Including: kiss-cuts, creasing, milling-routing, punching, engraving and angle cutting.
• Produces highest yields per inch of material with computer-guided nesting software to get the most cuts that leave the least amount of matrix (waste material).

Considerations 

• Lower throughput than die methods. 

Waterjet Cutting

Waterjet cutting is another die-less method. It uses a pressurized stream of water from a computer-guided nozzle to cut shapes from flexible material with exceptional precision.

Advantages: 

• High precision to achieve narrow tolerances and dimensions. 
• Suitable for small volumes, prototyping and proof of concept. 
• No hardware costs as it eliminates the need to source custom-metal dies.  
• Achieves smooth edges, particularly from more challenging material such as foams and rubber that are rigid, thick or dense. 

Considerations 

• Longer throughput per unit increases production time, which can make large volume runs cost-prohibitive. 

Laser Cutting

A software-guided laser beam focuses heat onto sheet material to make precise cuts. 

Advantages

• Optimal for jobs with a fast turnaround and prototyping, similar to other dieless methods.  
• Produces intricate and delicate shapes with high precision, particularly from thin sheets of material. 

Considerations 

• High temperatures from the laser can leave burns and melted areas along the edging (known as the heat-affected zone), potentially impacting the gasket’s performance and appearance.
• Not suited for thicker materials, longer cutting times extend the heat-affected zone.  

Our manufacturing expertise, your benefit  

In manufacturing, every cent counts and the die-cutting method chosen by your custom converter will have a big impact on production volume as well as the quality of the product. Both have a large impact on the cost of your custom gasket. 

SRP has the latest equipment and manufacturing expertise to achieve the best production efficiency and gasket quality for your order. Contact us today to discuss your latest project. 

There’s no escaping electromagnetic waves. They occur naturally in the air, but they also emit from high-frequency devices. That’s a reality in our connected world. When it comes time to release your electronic device to the market, adequate EMI shielding is essential, otherwise the risk of exposure ranges from disruptive to damaging.

In the worst-case scenario, EMI causes data corruption, surges in voltage, current overload and overheating, any of which can shorten the lifespan of the device. (It’s no wonder hospitals, gas stations and airlines insist we keep our smart phones powered down around expensive equipment.)

EMI shielding tape provides a lightweight multi-purpose solution, as it simultaneously shields and holds components in place. But there’s one unfortunate reality in product design: Some substrates have many beneficial properties for electronic components, but present challenging design hurdles. That’s where engineers and product designers apply problem solving while keeping costs to a minimum.

When innovative new products unlock new solutions for challenging designs, it’s a game changer for OEMs. Recently, 3M introduced its 5113 series of electrically conductive tape, designed to adhere to some of the most challenging-to-bond surfaces while providing enhanced performance in EMI shielding.

What’s unique about the 3M 5113 series of electrically conductive tape?

This series of EMI/RMI high-performance shielding tape features polyolefin adhesive and a conductive matrix – giving you the combination of low-energy surface bonding with robust EMI shielding.

3M innovation: Polyolefin as a pressure-sensitive adhesive

The innovative polyolefin pressure-sensitive adhesive greatly enhances your versatility in electronic product design. These adhesives are designed specifically for bonding low-energy surfaces like polyethylene and polypropylene. These polymers are favored across multiple industries because of their low cost, lightweight properties, chemical resistance and durability. While these properties can make ideal components for electronic devices, bonding these low-surface energy substrates can be a struggle. The availability of polyolefin pressure-sensitive adhesive eliminates the need for more labor-intensive fastening methods.

Conductive components

The conductive fabric carrier and conductive adhesive gives the electrical current a path that provides reliable shielding against harmful electromagnetic waves, offering protection for sensitive components against damage.

Solutions and benefits of 3M 5113 series of electrically conductive tape

Configurations

• 3M Electrically Conductive Single-Sided Tape 5113SFT-50 for dynamic shielding and covering applications
• 3M Electrically Conductive Double-Sided Tape 5113DFT-50 for complex grounding applications

Benefits

• Four-year shelf life to deliver a reliable, consistent performance
• Greater design flexibility and versatility
• Higher temperature resistance: Long term, up to 105 degrees Celsius in humid conditions
• High adhesion and strong bonding to some low-energy surfaces, reducing the need for primers
• Highly comfortable, allowing for precision in placement in tight spaces to create EMI sealed bond lines
• Helps control signal interference through PIM mitigation for higher signal integrity and performance

Applications

• Circuit interconnection
• Camera module grounding
• Electrostatic discharge (ESD)
• EMI shield and gasket attachment
• Shield can lid
• PCB/flex/chassis grounding
• Bond line gap shielding
• Medium pitch flexible circuits and PCBs
• PIM management

Industries

• General industrial electronics
• Aerospace and defense electronics
• Appliances, automotive and IoT devices
• Communications infrastructure
• Medical equipment

Source: 3M Electrically Conductive Tapes 5113 Series

EMI shielding solutions from SRP

Is the 3M 5113 series the electronically conductive tape you’ve been seeking? Talk to the experts at SRP. We collaborate with leading brands like 3M to identify the best materials for your project, procure what you require and precision die-cut to meet your exact specifications.

Send us your CAD file and project requirements to get a prompt and hassle-free quote. Contact us today.

Electronic devices are remaking our world. But they can also be dangerous when they’re not designed and manufactured with the end user in mind. Headlines about exploding laptops, hoverboards and smartphones in recent years are damaging to brands and put consumers at risk.

What’s causing these explosions? Look to the technological advancements that make these gadgets lighter, smaller, more powerful and portable. They produce more heat in smaller spaces compared to that of their predecessors. When devices lack proper heat and temperature management materials, the results can be catastrophic.

Then there’s the lithium-ion battery. Powerful, fast-charging and long-lasting, they also produce heat in the course of charging and discharging.

Excess heat degrades battery performance and battery life, or, worse, causes thermal runaway where the battery combusts or explodes. Prolonged exposure from high heat also damages components, shortening the life of the device.

Heat and Temperature Management Solutions by SRP

SRP’s inventory of heat and temperature control materials can help you overcome the challenges of designing compact, battery-powered electronic devices that end users can feel safe about using. The trust of your brand is at stake. Let us help you identify the best solution.

Thermally Conductive Tapes

Designed for high thermal conductivity to effectively transfer heat away, they come in various adhesive strengths and can be custom die-cut into the exact dimensions to integrate with your product. Streamline your design while enhancing heat and temperature control.

Insulating Tapes

Features insulation properties that prevent heat transfer where it’s not wanted. These foam-backed tapes come in various thicknesses that can be customized with the desired adhesive properties.

Thermal Interface Materials (TIM)

Made of lightweight material, thermal interface materials can be placed directly on the surfaces of delicate electronic components without damaging them. They also conform to rough and irregular surfaces to eliminate pockets and gaps — spaces where heat collects and builds. We custom die-cut thermal interface material to bridge components directly to the heat sink and completely fill the gaps. Heat is dissipated and components operate safely for their expected life span.

Closed-Cell Foam Insulation

Lightweight insulation shields sensitive elements from outside heat sources or other heat-generating elements. These may be custom die-cut and laminated to pressure-sensitive tape for sealing and gap filling. Because these insulating foams are available in a range of thicknesses and densities, they offer a versatile solution to meet the needs of just about any electronic design.

Conductive Foam

Lightweight foams are also formulated to provide conductivity for thermal management. Available in various compression strengths and conductivity levels for gap filling and sealing applications.

SRP Solutions to Enhance the Protection of Electronic Devices

Protect end users from the dangers of heat buildup in electronic devices with custom die-cut components by SRP. We’re well-equipped to pinpoint the solution for complex and challenging designs. As a Preferred Converter to 3M and other top brands, we have access to technical support with specialists in every industry to help you identify the most protective and efficient materials. Then we custom die-cut your chosen materials to your specifications, using the most accurate and efficient machining method.

Send us your CAD file and project requirements to get a prompt and hassle-free quote. Contact us today.

Can tape make your electronic device safer, more reliable, longer lasting? Die-cutting adhesive tapes is the go-to for securing gaskets, panels, screens, batteries and other components in portable and wearable devices. However, there’s a plethora of tape products made with specially engineered foams, films and adhesives that can also safeguard sensitive components as well as the battery system.

That’s critical because devices get around. Whether you’re talking about laptops, smartwatches, tablets or the latest smartphone, batteries and electronic components demand protection from the hazards of normal use as well as rough handling.

Protective benefits of die-cut adhesive tape in electronics

• Reliably seal out dust and water.
• Absorb and cushion against shock, impact and vibration
• Heat dissipation to prevent overheating.

The need for protection: The future is portable and battery-powered

As our world becomes increasingly electrified, connected and portable, demand will continue to increase for lithium-ion battery systems.

Lithium-ion-powered electronic devices have forecasted 14.5% market growth between 2023 and 2032. Tablets and PCs are driving nearly one-third of global revenues for Li-ion powered electronics. Their leadership position is expected to remain over the coming decade, though smart, wearable devices will also contribute to demand.

Key considerations for die-cut tapes in electronics: Rugged protectiveness

Lithium-ion batteries deliver many sought-after properties in today’s portable devices. They’re lightweight, retain capacity after thousands of charging cycles, fast-charging and have a long lifespan.

To keep lithium-ion batteries safe and operable in electronic devices, two key considerations are top of mind:

• Thermal runaway: Heat or high impact that damages the highly flammable electrolytes within the battery cell can result in thermal runaway and combustion, setting the table for an explosive situation.
• Water and oxygen exposure: Lithium-ion batteries also require protection against moisture and oxygen. Cracked housing or total submersion in water can reduce performance and render the battery inoperable.

This gets to another important thing to consider about personal electronics: They’re personal.

Laptops, smart watches and smartphones are in near-constant contact with the end user. They’re worn, stored in pockets and transported in bags and backpacks, within reach 24/7. They’re subject to exposure to varying environmental conditions and temperature changes, accidental drops on hard surfaces and in water, and so on.

These devices demand enhanced protection of the battery against impact, vibration, heat and moisture. Tape selection around some of these protective properties can ensure the longevity and performance of these devices.

Considerations in choosing die-cut tapes for electronics

• Bonding strength
• Resistance to environmental conditions
• Conformity to curved or irregular surfaces
• Consistent adhesion for the life of the product
• Temperature resistance
• Vibration and shock absorption

Die-cut solutions with 3M tapes for personal electronics

3M VHB Tape 4301R

• Application: Bonds plastic to glass, such as monitor panels.
• Properties: Invisible, leakproof fastening with a durable bond.

3M VHB Tape 4914

• Application: Bond plastic to silicone pad; bond plastic to inked-glass; waterproofing for battery button; laptop bezel bonding.
• Properties: Closed-cell technology provides exceptional sealing performance for waterproofing and high-drop resistance.

3M VHB Tape 5909

• Application: Bond plastic to glass. Sealing and protection for front displays and back covers for tablets and smartphones.
• Properties: Enhanced waterproofing, conformability, surface adhesion, sealing and impact resistance.

3M VHB Tape 5980

• Application: Seal displays, speakers, microphones, volume keys. Bond metal to glass. Bond mesh to plastic. Stabilize battery in wearable devices.
• Properties: Exceptional shock absorption, bonding and sealing, enhanced waterproofing.

3M Double Coated Tape 93010LE & 93015LE

• Applications: Bond curved plastic to foam or plastic, and other hard-to-bond materials for a sleek finish.
• Properties: High bond strength, high shear strength when engineered with 3M™ Adhesive 300LSE.

3M Double Coated Tape 93420

• Applications: Apply touch panel to metal for tablets and notebooks. Bond glass to plastic.
• Properties: Re-workability, anti-lifting, conformable and drop resistance.

3M Conformable Double Coated Tape 93425

• Application: Bonds glass to plastic.
• Properties: Drop resistance for touch panels.

3M Adhesive Transfer Tape 9471LE & 9472LE

• Application: Bond plastic to flexible printed circuits. Bond metal plating to plastic.
• Properties: Anti-lifting, durable bonding when engineered with 3M Adhesive 300LSE

3M Adhesive Transfer Tape 96105CR

• Application: Bonds glass to flexible printed circuit.
• Properties: Resists water, sweat, perfumes, skin oils and chemicals.

Enhance protection of electronics and battery systems

Protect power sources and the inner intelligence that brings life to smart screens with the power of die-cut adhesive tape. Our decades of converting tape into specialty shapes combined with our longtime partnership with 3M produce reliable solutions for our customers. We’re well-equipped to pinpoint the solution for complex and challenging designs. As a 3M Preferred Converter, we have access to 3M technical support with specialists in every industry.

Send us your CAD file and project requirements to get a prompt and hassle-free quote. Contact us today.

Industrial foam tapes have gained a lot of traction in the automotive assembly, overtaking screws, welds and rivets and other fasteners used to bring together components. The reason for this evolution is clear: Acrylic foam tape delivers a bond that lasts the life of the vehicle, while enhancing design aesthetics and improving the ease of installation. In the following, we’ll cover the benefits of these acrylic foam tapes and top products for automotive applications.

3M Acrylic Foam Tapes for Automotive: The Benefits

3M acrylic foam tape was a game changer for the automotive industry for transforming the performance and production efficiency of joining two components.

With no welding or machining required, acrylic foam tape saves on skilled labor. The absence of metal screws makes components lighter, which is favorable for fuel efficiency, and reduces noise. Paired with the sound absorbing core, acrylic foam tapes provide a quieter, more pleasant ride for the end user.

Another advantage of using 3M acrylic foam tape is how it improves the appearance of automotive components with a smoother, streamlined aerodynamic design. There’s no drilling into painted or clear coat surfaces, which in turn reduces the appearance of rust in the long term.

Properties of 3M Acrylic Foam Tapes for Automotive Applications

The mechanical properties of Acrylic Foam Tapes by 3M make it a durable, reliable option for automotive applications. Acrylic adhesive resists degradation from exposure to weather, including temperature fluctuations, UV rays and moisture during the life of the product.

Its foam core is designed to dissipate forces when exposed to high stress load.

This product is also industry approved. Since 1978, 3M acrylic foam tapes have met product and design engineering requirements for automotive applications.

Top Applications of 3M Acrylic Foam Tape

• Attaching trim parts
• Bonding seals throughout the car body
• Door and window seals
• Door cladding and inlay
• Roof rails
• Spoiler
• Rocker panel / body side molding
• Parking sensor retainers

Selected 3M Acrylic Foam Tapes

3M Acrylic Plus Tape Series PT1000: This black, double-coated acrylic foam is designed to attach automotive exterior trim parts, including claddings and body side moldings. Some of its properties include high conformability with a high-strength core with low elongation properties and cold-temperature impact resistance.

3M Acrylic Foam Tape GT7100: Commonly used for attaching emblems, nameplates, moldings, step pads and other automotive trims. When applied to traditional paints, this gray, acrylic foam tape has excellent adhesion. It demonstrates excellent conformability and wet out on a range of automotive applications. It maintains adhesion through shrinkage and elongation caused by temperature changes, while simultaneously maintaining good stress relaxation properties. Provides very good final adhesion and peel strength and performs well in a wide range of weather, solvent and temperature exposures.

3M Acrylic Foam Tape RT8000: Developed specifically for attaching trim and other exterior parts. Its acrylic adhesive formula is designed to provide excellent adhesion to traditional auto paint as well as advanced paint systems. It’s strong enough to support heavier parts, including spoilers and claddings, while providing stress relaxation during exposure to high loads.

Automotive Acrylic Tape Solutions from SRP

Find the solutions for any automotive design with SRP’s extensive design knowledge, reinforced with our longtime partnership with 3M. As a 3M preferred converter, we have access to 3M technical support with specialists in every industry, so we can pinpoint the solution for even the most complex and challenging design.

Send us your CAD file and project requirements to get a prompt and hassle-free quote. Contact us today.

When choosing a custom converter for mass production of gaskets, it is essential to delve deeper and understand their competencies and business practices.

In today’s competitive market, striking the right balance between value and quality is crucial. When choosing a custom converter for mass production of gaskets, it is essential to delve deeper and understand their competencies and business practices. By examining certain key areas, exceptional converters can deliver exceptional value through efficiency. At SRP, these areas of focus have allowed us to provide outstanding results for our customers.

Materials Selection

Material selection is a critical aspect where an experienced custom converter can save you time. We can pinpoint the precise pressure-sensitive adhesive and foam material for the job — the one that performs best for the application, while enhancing the durability, functionality and quality of the end product. Look for converters with preferred partnerships with multiple suppliers, demonstrating a high level of expertise with their products. At SRP, our longstanding partnerships with top brands like 3M reflect the trust and confidence they have in our ability to represent their brand effectively.

Testing

Testing and prototyping are essential steps in the process, and a converter’s approach should facilitate rather than hinder these stages. Understanding the converter’s prototyping process, machining capabilities, and timelines for producing and shipping samples is vital to ensure a smooth and efficient development process.

Tolerance

Making the right call on the tolerance range of your part is essential to managing your costs. Whenever you die-cut foam and sponge material, some variability in the dimensions is expected between parts. The reason is when the machine cuts into the flexible material, it causes material compression, deflection and concavity. When you’re calculating specifications for soft components, you’ll want to adopt a tolerance range that’s probably wider than what you would normally choose for a hard component. But a skilled custom converter can calculate the optimal tolerance range for your gasket. This results in higher volumes of high-quality parts while minimizing material waste and production time.

Machining

Efficiency is at the core of lean manufacturing practices. Selecting the right machining process for specific materials is key. Different foams and sponges used in gasketing require tailored approaches to achieve the desired outcomes. By designing a production plan centered around efficiency, quality and waste reduction, a custom converter can help you optimize costs without compromising on the final product.

Communication

Effective communication and collaboration are fundamental to successful partnerships. At SRP, our independent structure allows us to prioritize clear communication, ensuring fast and reliable responses at every stage of your project. With a single focus on creating exceptional parts from flexible materials, we eliminate bureaucratic hurdles, providing you with a seamless experience. When you call us at any stage of your project — quote, update, order change, problem-solving — you’ll always have access to fast answers.

When you partner with an exceptional converter like SRP, you can achieve exceptional value through efficiency. From start to finish, we’ll help you achieve high-quality results while optimizing costs so you can deliver the best possible product for your customers. Contact us today!

In the world of flexible material cutting, the choice between kiss cutting and die cutting can significantly impact the outcome of a project.

In the world of flexible material cutting, the choice between kiss cutting and die cutting can significantly impact the outcome of a project. Tolerance requirements, the efficiency of the method and material considerations all play a pivotal role in determining the most suitable method for machining custom parts from your chosen material.

In the following, we’ll outline the differences between kiss cutting and die cutting, along with some of the core factors that inform which machining method we choose for your part.

Kiss Cutting vs. Die Cutting: What’s the difference?

Die cutting is a term that’s often used to describe machining custom shapes from a material. The most common method uses a sharp steel die to cut shapes from the layers of foil, film, foam and adhesive. Kiss cutting is one of several die-cutting methods, and it’s often used to create a roll or sheet of peel-and-stick gaskets on a release liner.

Die Cutting

• Die cutting is a term that’s sometimes used interchangeably with through-cuts, which is when the die punctures through all layers of material, and meets the metal anvil.
• Flatbed die cutting is the most standard and oldest method for cutting identical shapes out of rolls and sheets of foam, tape and other flexible material.
• Much like a cookie cutter, the sharp-edged die or a steel rule is pressed directly into the material using a hydraulic press until it meets the metal anvil on the other side.
• After cutting, the part is completely separated from the remaining matrix, or waste material.

Kiss Cutting

• The counterpart to through-cuts, as the die does not pass through all layers of materials.
• The die is calibrated to end the cut at the very top layer of material that needs to remain uncut. For most kiss cuts, the uncut material would be the release liner. Once the cut is made, the matrix, or waste material, is cleared away, leaving the shapes on a liner.
• The most common machine method for kiss cutting is a rotary die press. But kiss cuts can also be achieved with a software-guided laser cutter, where the beam cuts down into the specified depth of the material.

Other considerations when choosing between die cutting and kiss cutting

There’s no one cutting method that suits every job. That’s why we plan production around what achieves the highest quality at the best value to you. Here are just some of the top considerations that factor into the decision of which machining method is best to produce your part.

Tolerance Requirements and Material Considerations

For parts that require a tailor fit with little deviation, flatbed die cutting will achieve the most precise dimensions with sharper edges, as the cuts are performed straight into the material.

Rotary die cuts made with a cylindrical die are less suited for thicker foams and sponge materials, particularly for jobs with narrow tolerance requirements. In these instances, flatbed die cutting can provide an alternative that produces the results you’re looking for. However, for thinner materials, rotary die cutting and laser cutting can yield tight tolerances.

Which Method Is Most Efficient?

Rotary die cutting can produce a higher output in less time than flatbed diet cutting, whether used to make kiss cuts or through cuts. (Rotary die cutting is capable of achieving both.) As the cylindrical die rolls over the material, it’s constantly producing shapes, making it ideal for high-volume jobs.

When used for making kiss cuts, rotary die cutting is a method that also makes assembly more efficient. When the gaskets and other types of adhesive-backed parts are presented on a release liner — whether on a sheet or a roll — the parts are easy to remove, easier to handle and require no sorting.

Flatbed die cutting, on the other hand, is more ideal for through cuts and kiss cutting thicker materials. It offers a rapid changeover, but the machining is slower than the rotary method as the hydraulic press stamps out one shape at a time.

When done well, kiss cutting is highly efficient and keeps material waste to a minimum. However, kiss cutting requires highly skilled machinists and ongoing monitoring for quality control and to make sure the die is achieving those precise cuts. Otherwise, cuts that are too shallow can ruin the parts on the liner.

By understanding these differences and considering the specific needs of each job, it’s important to make informed decisions that lead to the best quality results. With the guidance of experienced converters like SRP, achieving precision and efficiency in shaping flexible materials becomes a reality. Contact us today to discuss your latest project!

At SRP, we understand the significance of selecting the best-performing materials for fabricating custom gaskets and seals for EV battery systems.

The transportation industry is on the cusp of a major evolution, with electric vehicles (EVs) leading the way. As the market continues to accelerate, the choice of gasket and sealing materials becomes increasingly critical. We’ll explore the reasons behind the shift from internal combustion engines to lithium-ion-powered cars and delve into the essential role gaskets and seals play in ensuring the performance and safety of EV battery systems.

The growth of the electric vehicle market

To set the stage, let’s consider the remarkable growth of the electric vehicle market. As of October 2022, there were 1.9 million EVs in operation in the United States, accounting for 0.7% of the total 281 million vehicles on the road. Projections by S&P Global Mobility suggest that by 2030, four out of every ten vehicles on the road will be electric.

This surge can be attributed to various factors, including government incentives, expanding battery manufacturing capacities, increased consumer demand for eco-friendly options and the declining costs of lithium-ion batteries.

The importance of battery performance and safety

With the future of transportation at stake, ensuring the success of EVs is paramount. Battery performance and safety are pivotal factors in achieving this success by preventing thermal runaway, achieving consistent and reliable battery range, and maintaining charging performance. EV battery systems must withstand demanding conditions, requiring rugged gaskets and seals that protect against temperature extremes, UV exposure, wind, moisture ingress and sudden impacts.

Key performance criteria for gaskets and seals in EV vehicles

To meet the performance and safety requirements of EV battery systems, gaskets and seals must excel in several areas. These criteria include:

• Vibration absorption
• Isolation of extreme heat or fire incidents
• Optimization of overall performance
• Protection against temperature impact and environmental ingress
• Thermal insulation for heat-sensitive components
• Fire protection and shielding against EMI interference
• Compression set resistance throughout the product’s lifespan

SRP: Your Trusted Resource for Custom Gaskets and Seals

At SRP, we understand the significance of selecting the best-performing materials for fabricating custom gaskets and seals for EV battery systems. Through our preferred partnerships with top brands of adhesives, films and elastomeric materials, we ensure the highest quality die-cut components. Our experienced team can fabricate these materials to your exact specifications and deliver them directly to you.

Applications of gaskets and seals in EV batteries

We provide a range of die-cut solutions for gasket and sealing applications for EV batteries, including:

• Battery packs
• Sealing for battery modules
• Battery covers
• Venting caps
• Cooling plate and liquid delivery system
• Battery cells
• Terminal isolation

Gaskets and seals play a pivotal role in meeting the performance and safety requirements of EV battery systems. By selecting the right materials for your components and die-cutting them to your exact specifications, we can help ensure the longevity, reliability and efficiency of EV battery systems. To learn more about our offerings and how we can enhance your EV battery systems, contact the experienced team at SRP.