Why Battery Pads Matter in EV design 

A vehicle’s operating environment is full of forces that can wreak havoc on a battery system — particularly mechanical stress, shocks and vibrations.

While electric vehicles (EVs) do provide a much smoother ride compared to traditional gas engines, the battery pack — whether made of pouch, prismatic or solid state batteries  — still requires adequate cushioning and shock absorption for safe and reliable operation. All the while, these high energy batteries require consistent pressure. 

Enter the battery pad. PORON EVExtend® Battery Pad Material provides the required level of firmness required in higher-energy batteries used in EV and hybrid vehicles, offering long-term performance and functionality in your EV battery design. 

In this blog, we’ll outline what it does and how it will enhance battery performance and safety, and how SRP can customize it for your needs. 

What is PORON EVExtend Battery Pad Material?

PORON EVExtend Battery Pad Material is a high-performance option that’s designed to endure the stresses that are unique to the EV operating environment. 

EV battery cells expand and contract to a great degree during charging and discharging cycles. To address this, PORON EVExtend® provides the right balance of compression set resistance and stress relaxation. It’s compressible material that offers that just-right, Goldilocks level performance by: 

• Flexing with the cycles of expansion and contraction
• Maintaining adequate pressure to hold batteries securely in place. 

But its main advantage comes from its durability. PORON EVExtend is engineered for long-term durability, retaining its cushioning and protective properties throughout the battery’s lifecycle. 

Key Benefits of PORON EVExtend 

• Constant pushback force: Maintains steady pressure to hold cell batteries in place. 
• Dynamic response: Adapts to fluctuations during charging and discharging cycling. 
• Extended life: Retains compression and maintains original thickness for the life of the battery.  
• Temperature resilience: Operates under a wide range of temperatures, from -20 degrees Celsius to 121 C.  (Recommend constant use 90 C.) 

Custom PORON EVExtend for your design 

As a longtime Preferred Converter of Rogers Corporation, SRP offers unmatched expertise in converting PORON EVExtend into precise components for your EV battery pack. 

• Direct sourcing: We procure EVExtend directly from the manufacturer. Count on high quality, expedited shipping and competitive pricing. 
• Custom die-cutting: Our decades of advanced die-cutting experience mean we can shape PORON EVExtend to fit your EV battery back with precision, even at high volumes. 

Learn more about our precision die-cutting services. 

Learn more about EV materials in our latest Ebook, The Future is Electric: An OEM’s Guide to Sourcing Die-Cut Battery Components for EV Production. 

Start Your Project with a Trusted Rogers Converter

Ready to get started on your EV project? Contact the team at SRP, and we’ll prepare a fast and accurate quote. 

What’s the most critical element of product design? It often comes down to the materials and how well they support the application.

That’s why SRP is excited to announce we now have direct access to a specialized manufacturer of silicone sponge extrusions: ​​expanSil™ by Silicone Engineering. 

To learn more about the features and available products in the expanSil line, visit our dedicated page, which provides all the key details. 

Why use customized silicone sponge extrusions? 

What’s the advantage of sourcing silicone sponge extrusions through SRP? 

Customization: You can customize it and get exactly what you need. Thanks to our direct access to expanSil™ products, all your silicone sponge extrusions are made-to-order. You can select from a wide range of shapes, widths, and colors to perfectly suit your application.

Higher quality: When material quality is essential, sourcing your silicone extrusions from SRP offers a superior alternative to off-the-shelf products. Unlike purchasing stock items, you’ll have sponge extrusion that meet your exact specifications and are manufactured by a company with a strong reputation for quality control. 

Supply chain stability: Customization ensures enhanced reliability and performance, while also reducing the risk of supply disruptions. By working with SRP for your custom extrusions along with all your other custom converted materials, you’ll streamline your vendor relationships. With fewer vendors comes better pricing and improved efficiency.

How to get a quote for custom silicone extrusions 

To help you begin your order with SRP, use our checklist on what you need to know for a smooth, hassle free process. 

For custom silicone extrusions, the order process will depend on whether you’re working with an existing formulation or if you’re seeking a new formulation for a new application. 

What do I need to get a quote on an existing extrusion? 

For a fast and accurate quote from SRP, please provide the following information: 

1. A drawing (if available)
2. Material specifications
3. Color requirements 
4. Length requirements 
5. Per purchase quality and frequency
6. Estimated Annual Usage (EAU) to help secure the best freight rates
7. Current packaging method (e.g., coiled, boxed, reel or bagged)

Additional tips for hassle-free ordering 

• When quoting for tubing, providing the Inner Diameter (ID) and wall thickness — rather than the ID and Outer Diameter (OD) — ensures the tubing remains concentric, maintaining a uniform wall thickness. This consistency is essential for structural integrity and reliable performance.
• For extended rolls, material splicing is available to join pieces into a continuous length.
• Note: Silicone Engineering does not extrude shapes with inserts (e.g., wire, metal), dual durometer shapes, or any EMI/RFI conductive materials.

What do I need to get a quote on a new extrusion? 

If you’re sourcing a custom silicone extrusion for a new application, we’ll need a few additional details beyond the basics to get you an exact match:

1. A drawing 
2. A description of the application 
3. Material specifications including
   • Hardness 
   • Compression set 
   • Closure force 
   • Solid or sponge 
   • Adhesive (if needed)
4. Environmental conditions, including:
   • Operating temperature 
   • Chemical resistance 
5. For lighting applications: Light housing lens material (to assess outgassing) 

Your quote will include a recommended material based on an analysis of the information you provided, along with relevant data sheets and cross-sectional tolerances.

SRP: Your Complete Resource for Custom Materials and Components 

Whether you’re seeking a new vendor for silicone sponge extrusion or identifying the best formulation for a new application, our team is here to help. Get started by filling out our online form for your fast and accurate quote today. 

The LVO Family of 3M^TM VHB^TM Tape clears the air for your end users, without sacrificing the bonding strength or durability you’ve come to expect. 

With this recently added family of 3M^TM VHB^TM tape, you can significantly lessen the effects of off-gassing, which are associated with the vapors, unpleasant odors and fogging of newer materials. This helps OEMs create a more breathable environment for their end users. 

The most common applications for 3M^TM VHB^TM Tape LVO Family include home appliances, where contact with food is a consideration, as well as automotive interiors, where small enclosures intensify the impact of off-gassing. 

However, any industry looking to reduce emissions from adhesive tapes can benefit from 3M innovation. 

As a longtime Preferred Converter of 3M^TM, SRP has the trusted experts to help you refine your selection of 3M^TM VHB^TM Tape before die-cutting it to your exact specifications. 

What are VOCs and why do they matter in adhesive tape applications?

3M^TM VHB^TM (Very High Bonding) Tape has been a favorite among engineers and product designers since its introduction in the early 1980s. With an acrylic adhesive strong enough to provide a viable alternative for metal fasteners, 3M^TM VHB^TM tape transformed how multiple industries designed and assembled their products. 

Like many industrial tapes used in gasketing and bonding, the acrylic adhesive in 3M^TM VHB^TM tapes contain volatile organic compounds (VOCs), which can be emitted into the air for up to six months after application. 

These emissions are harmless in environments where they can easily be vented away. However, they can pose challenges in enclosed spaces, especially when users are sensitive to air quality.

Reducing VOC emissions in critical applications

• Automotive: In confined spaces like vehicle cabins, OEMs aim to reduce the intensity of the “new car smell,” often caused by VOCs.
• Home Appliances: For kitchen appliances, brands prioritize minimizing VOC emissions to prevent negative perceptions and potential contamination in areas where food is prepared.

How effective is VHB^TM Tape LVO Family at reducing emissions? 

3M^TM VHB^TM Tape Low LVO Family provides the same durable, high-performance bonding that has made VHB^TM Tape a staple across multiple industries. But it’s made from a specially engineered acrylic adhesive that leaves the environment a little fresher in applications where good air quality is paramount. 

Compared to standard acrylic tapes, the LVO tapes produce: 

• 85% reduction in VOCs 
• 80% reduction in fogging 

3M^TM VHB^TM  Tape LVO Family also meets industry standards: 

• Specially engineered to deliver low odor (VDA 270) and low VOCs and fog emissions (VDA 278), it is thoroughly tested by third-party methods to meet higher standards such as in the automotive industry. 
• Compliant with FDA 21 CFR 175.105 for indirect food contact, making it suitable for kitchen appliances and other applications where keeping emissions minimal are a concern. 

What are the features of 3M^TM VHB^TM Tape LVO Family? 

Now that we know that 3M^TM VHB^TM  LVO Family emits tangibly reduced emissions, does it provide the same level of bonding performance? The short answer to that is yes. Before choosing any pressure sensitive adhesive, resources like the technical data sheet can confirm whether it’s the best solution for your application. 

• Exceptional bonding to low-surface energy substrates, like polypropylene and polystyrene 
• High-heat performance, with adhesion performance withstanding temperatures up to 250 °F (121 °C)
• Can be used as a replacement for metal fasteners, including rivets, welding and screws. 
• Permanent sealing against water, moisture, dust and other elements 
• Fast application with bonding on contact, reaching immediate handling strength 
• Effective with bonding thinner, lighter weight and dissimilar materials 
• Leaves nearly invisible lines for streamlined designs and smooth surfaces 
• Foam type: Very conformable acrylic foam
• Adhesive type: Especially engineered Low VOC acrylic adhesive 

Partner with SRP: Lower emissions, exceptional bonding and a precision fit  

From prototyping to final production, SRP helps you achieve low-emission, high-performance results with 3M™ VHB™ Tape LVO. Upload your CAD file to request a fast quote. 

When manufacturing gaskets, understanding compression set is vital for ensuring long-lasting performance. If a gasket loses its original thickness due to force and pressure, gaps in the barrier can form. These gaps may allow fluids or gases to enter or leak, leading to potential equipment failures.

In this article, we’ll address your most pressing questions about compression set and guide you in selecting the right materials.

What is Compression Set in Gaskets?

Compression set refers to permanent deformation in foam gasket materials. When made from materials engineered to compress, these gaskets create a dense barrier that seals out moisture, dust and other contaminants.

Over time, continuous pressure can permanently alter the foam, resulting in a permanent loss of thickness. In other words, the gasket doesn’t fully rebound after compression and may no longer maintain a reliable seal. Compression set occurs when a material becomes permanently deformed after prolonged exposure to pressure.

How is Compression Set Measured and Calculated? 

Compression set is measured as a percentage. As you compare materials, a lower percentage indicates the material can better withstand long-term pressure without becoming permanently deformed or taking a compression set. 

Compression set is calculated by measuring changes in the material’s thickness after it’s been compressed. The calculation is based on the material’s original thickness, recovered thickness and the thickness of the material in a compressed state (test thickness), using the following formula: 

Compression Set (%) = [(Original Thickness – Recovered Thickness) / Original Thickness] × 100

A lower percentage indicates the material returns more closely to its original thickness after being compressed, which is preferred for sealing applications that require long-term resiliency.

Reading the data sheets on compression sets 

Compression set is evaluated under standardized test conditions, such as ASTM D395 for solid rubber, ASTM D1056 for sponge rubber, or DIN 53517 for cellular foam materials like PORON polyurethane and HyPUR-cel polyurethane. 

These standards help ensure that materials are tested under consistent conditions, so you can make fair comparisons between options during material selection.

It’s important to note that compression set values listed in technical data sheets may differ from real-world applications due to controlled lab testing. Use the data to narrow your selection, but always test prototypes to identify the best fit for your specific needs.

SRP offers rapid prototyping so you can launch test use cases immediately. 

How Low Should Your Compression Set Be?

Choosing an acceptable compression set value depends on the application and material used. In general, a compression set value of less than 25% is considered adequate for most gasketing applications. However, critical sealing applications, such as medical devices, might call for a lower compression set value of 10%. The same is true for reclosable seals. 

For further reading: PORON Selection: Choose the Right Product to Achieve Compression Set Resistance

While it may seem logical to select materials with the lowest compression set for durability, we recommend considering overall value for your specific application. Sometimes, a more affordable material with a higher compression set can perform just as well, making the higher cost unjustifiable.

Our promise at SRP is transparency; we’ll inform you if you’re overspending based on our expertise. Learn more about SRP’s time-tested strategies to control your die-cut gasket costs. 

How to Choose the Best Material Based on Compression Set 

Selecting the right material to address compression set requires real-world testing to ensure performance under intended conditions.

For reclosable seals — like those on doors or detachable units — a soft material with a low compression set is ideal, as these materials can spring back to their original shape after being compressed. 

Many permanent enclosures perform well with materials that have a higher compression set. However, if these enclosures are opened for repairs or cleaning, it’s essential to inspect the gaskets regularly and replace them as needed for optimal sealing performance.

To get more insight on SRP’s added value as you refine material selection, download our case study on our resources page: Identifying the Right Gasket Material to Restore Function to a Gas Detector. 

Top-Quality Die-Cut Gaskets: Customized to your Application 

At SRP, we combine material expertise with advanced manufacturing techniques to create gaskets that deliver reliable, long-lasting performance.

Have a project in mind? Send us your specifications and we’ll provide a fast, accurate quote.

When it comes to using 3M™ VHB™ foam tape, precision is paramount. 

For decades, die-cutting was the go-to method to convert 3M^TM VHB™ and other foam materials like PORON and BISCO. In terms of overall efficiency and consistent quality, die-cutting came closest to hitting these targets. 

However, achieving close tolerances with thicker materials proved difficult at best. 

Today, however, thanks to advances in laser-cutting technology, project designers can now achieve more intricate dimensions and even tighter tolerances from VHB™ tape and other foam materials. 

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 more intricate, precise shapes from your custom adhesive backed gaskets. 

Die-Cutting vs. Laser Cutting: Understanding The Fundamentals 

Which is best for cutting foam tapes: 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. Overall, 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. 

Recent advances in laser cutting have made it faster and more precis, making it a more viable option even for thicker foam materials like VHB™ Tape. 

Greater precision in thick foam materials  

One of the most compelling advantages of laser cutting over die-cutting is its ability to cut very close tolerance parts from thicker foam materials like VHB™ tape. Here’s a comparison of their tolerance ranges: 

• Die-cutting +/- .030 inches
• Laser cutting:  +/- .005 inches

That’s a 6x improvement in dimensional accuracy — a major advantage for applications requiring tight part fits or clean edge finishes.

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. 

Greater material efficiency through nesting 

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. Sufficient space must be left for material displacement as the metal die slices through the material. 

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 also being a little gentler on the environment. 

Faster prototypes and design flexibility  

A key advantage of laser cutting is it offers greater range of design flexibility than traditional metal dies. 

The beam is guided by computer software, meaning all that’s needed is a CAD file to start production. Any last-minute design changes can be adapted immediately. Because laser cutting requires no custom tooling, it’s well-suited for quick-turn prototyping and rush orders. 

Kiss-cutting for easier assembly 

Another technological advancement of laser cutting is it can also perform kiss cuts — a technique where the laser cuts through the top layer of material and adhesive, but keeps the liner intact. 

This is ideal for applications where parts need to be easily handled and assembled, reducing the risk of damaging the adhesive during handling.

Best Materials for Laser Cutting (Gaskets, Seals & Pads)

Foam Materials

Laser cutting can cut precision shapes from foams, especially for complex geometries and tight tolerances.

• 3M™ VHB™ Tape (Acrylic Foam Core)
• PORON® Polyurethane
• BISCO® Silicone Foams
• EPDM Closed-Cell Foam
• Neoprene Sponge (Closed-Cell)

Adhesive-Backed Materials

Laser cutting is ideal for kiss-cutting and precision layering.

• 3M™ Adhesive Transfer Tapes 
• 3M™ Double-Sided Tapes
• Foam tapes with liners

Miscellaneous Specialty Materials

Laser cutting can also be applied to certain engineered materials:

• EMI Shielding Foils (with adhesives)
• Thermal Interface Materials (TIMs)

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. 

Send us your CAD file through our online form and we’ll get you a fast, accurate quote.  

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. Selected materials 
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. Selected Materials for Custom Gaskets     

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 materials 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, whether it’s a gasket that seals against weather conditions or a heat-resistent rubber gasket materials. 

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 of Gasket Orders 

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

The 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 for Gasket Orders

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. 

Ready to start your next project? Contact SRP today for expert advice, rapid quoting and high-performance gasket solutions.

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 Electromagnetic interference (EMI) can disrupt electronics, corrupt data, and shorten the life of devices.  For OEMs designing smaller, more powerful electronics, gaskets designed to provide effective EMI shielding is essential. 

3M™’s new 5113 series of polyolefin-based conductive tapes offers an innovative solution — delivering both reliable shielding and strong adhesion to hard-to-bond substrates like polyethylene and polypropylene. 

Challenges in EMI shielding 

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: Materials like polyethylene and polypropylene offer advantageous properties such as lightweight and chemical resistance but pose adhesion challenges due to their low surface energy.​

Innovations in EMI shielding 

When innovative new products unlock new solutions for challenging designs, it’s a game changer for OEMs. 3M™ has developed the 5113 series of electrically conductive tapes, engineered to bond effectively to challenging low-surface-energy substrates while offering superior EMI shielding performance.​

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

The 3M™ 5113 series incorporates a proprietary polyolefin-based conductive pressure-sensitive adhesive (CPSA) and a conductive matrix carrier, facilitating strong adhesion to low-energy surfaces alongside effective EMI shielding.

Traditional acrylic or rubber-based adhesives often require surface primers or mechanical fasteners to bond to LSE (low surface energy) plastics. The 5113 series eliminates this step, simplifying assembly while maintaining shielding performance.

3M™ innovation: Polyolefin as a pressure-sensitive adhesive

The polyolefin-based PSA in the 3M™ 5113 series enhances design flexibility by enabling reliable adhesion to substrates like polyethylene and polypropylene, which are traditionally difficult to bond.​

Conductive components

The combination of a nickel/copper/nickel-coated conductive woven fabric carrier and the conductive polyolefin adhesive establishes a continuous electrical path, ensuring effective EMI shielding and protection for sensitive electronic components. 

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

Configurations of 3M™ 5113 Series Electrically Conductive Tapes:

• 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

Key Benefits of 3M™ 5113 Series Electrically Conductive Tapes:

• 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 of 3M™ 5113 Series Electrically Conductive Tapes:

• 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 for 3M™ 5113 Series Electrically Conductive Tapes:

• General industrial 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. 

Why thermal management is critical in personal electronics 

Headlines about exploding laptops, hoverboards and smartphones in recent years highlight the importance of effective thermal management. Consumer safety and brand reputation are both at stake. 

What’s causing these explosions? Often, it’s a combination of factors — from battery defects or mechanical damage to insufficient thermal and circuit protection. As today’s devices become smaller and more powerful, they generate more heat in compact enclosures, increasing the importance of proper thermal management.

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. To mitigate the damage, effective heat management can help. 

Custom thermal management solutions by SRP

SRP can source the right heat and thermal management materials to 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 foams such as BISCO® HT-870 or BISCO® BF-1000 shields sensitive elements from outside heat sources or other heat-generating elements. These can be precision die-cut and laminated to pressure-sensitive tape for precise sealing and gap filling. Because these insulating foams are available in a range of thicknesses and densities, they can 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.

Read on to learn the benefits of thermal management gaskets 

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.