Die Cutting

Die Cutting Services from Sun Process Converting Inc.

At Sun Process Converting Inc., we are pleased to offer precision die cutting services, providing the design and manufacturing of die cut items for customers across a wide spectrum of industries.

Die cutting is a process in which a prefabricated metal or wood die is used to cut or stamp shapes from a sheet or a roll of material such as paper, paperboard, plastic, pressure sensitive adhesive tapes, and foam. The die cutting process is performed using a custom designed die in the desired shape. The material is held against a supportive substrate and the die is pressed or stamped into the material, quickly and efficiently cutting the material into the shape of the die.

Benefits of Die Cutting Services

There are several direct benefits of utilizing die cutting services for your business or personal needs. Some of the key benefits include:

• Increased Efficiency: Die cutting is a highly efficient process, allowing for large quantities of materials to be cut quickly and accurately. This can save time and money in production processes.
• Consistency and Precision: Using a custom designed die ensures that each piece is cut with the same precision and consistency, resulting in high quality products.
• Versatility: The die cutting process can be used on a variety of materials, making it a versatile option for various industries.
• Customization: With the ability to create custom dies, die cutting allows for unique and customized shapes and designs to be produced.
• Affordability: Die cutting is a cost effective solution for both large and small quantities, making it accessible for businesses of all sizes.

Industries that Benefit from Die Cutting

Die cutting services are utilized in a wide range of industries, including:

• Packaging: Die cutting is commonly used in the packaging industry to produce custom boxes, cartons, and containers.
• Automotive: The automotive industry often utilizes die cutting to create gaskets, seals, and other parts.
• Medical: With its precision and consistency, die cutting is ideal for creating medical devices and components.
• Electronics: The electronics industry uses die cutting for producing components such as LCD screens and touchpads.
• Textiles: From clothing labels to intricate fabric designs, die cutting is a valuable tool in the textile industry.

Our Die Cutting Services

Our die cutting services at Sun Process allow us to produce consistent, uniform, and repeatable shapes quickly and efficiently. Our specialized die cutting equipment is engineered to use the maximum amount of material surface for high production levels with low material waste. Depending on the material and application, a variety of die cutting methods have been developed for partial cuts, layered materials, and other production requirements. At Sun Process, we offer a wide range of die cutting services, which include:

• Rotary die cutting. Rotary die cutters use cylindrical rolling dies mounted on a gear mechanism. The gears turn to press the die against product material, thereby punching out the desired shape as the die rolls across the material surface. This process is highly efficient and precise, which makes it ideal for large scale production.
• Steel rule die cutting. Steel rule die cutting—also known as flatbed die cutting—uses a steel rule die mounted in a die board to push down against the substrate material. Once the shape has been created, a rubber or foam ejector built into the die board is used to eject the cut shape from the die board. This type of die cutting is not as quick as rotary die cutting, but it is the most common method used for thicker materials.
• Punch press. A punch press uses a die set to cut or press holes into a material. A die set for a punch press contains male and female dies on either side of the workpiece that combine to punch a hole when mated.
• Thermal die cutting techniques. Thermal die cutting offers a precise and efficient die cutting method, but is only compatible with materials that can be thermally displaced, such as vinyl and some plastics. Heat from electrical arcs or lasers precisely cut materials into the desired shape.

Value Added Services

Sun Process is pleased to offer a variety of value added services to supplement our die cutting operations, enabling us to provide a complete product on most orders without the need for additional processing or treatment by other vendors. Our comprehensive range of value added services includes:

• Film laminating
• Perforating
• Printing

Die Cutting Enhancements

At Sun Process, we understand that each project has different needs, and we offer a variety of unique enhancements, including:

• Tabs
• Back-slits
• Kiss cut
• Various liners
• Printed liners for instructions

Our die cut services are easily customized to meet the specific requirements of your project.

Material Types

Die cutting is a highly versatile process that can be used to produce products from a broad range of materials, including:

• Fabric
• Rubber
• Paper
• Foam
• Adhesives
• Plastics

Sun Process specializes in the production of adhesive backed materials, which require highly accurate depth calibration and specialized equipment to ensure that the adhesives are cut through without sticking to the cutting equipment or cutting through the liner. Through skillful manipulation of die bed elevation, cutting pressure, and blade length, our expert technicians can cut through multiple layers of adhesive material with the utmost efficiency and precision.

Superior Die Cutting by Sun Process

At Sun Process Converting, we pride ourselves on our ability to produce exceptional quality coated and converted materials. We offer a broad range of stock materials or can custom coat or convert customer supplied materials, as needed.

In addition to our precision die cutting services, we are pleased to offer coating and laminating, slitting, sheeting, flat cutting, and hot stamping services for nearly any industry. To learn more about our die cutting processes and how they can benefit your next project, contact us today to request a quote.

The Sun Process Converting Difference

At Sun Process, we are dedicated to providing the highest quality die cutting services in the industry. We pride ourselves on delivering precision, efficiency, and innovation to every project. Our experience, expertise, and commitment to customer satisfaction set us apart from our competitors.

We also understand the importance of staying current with emerging technologies and techniques in die cutting. That is why we continually invest in state-of-the-art equipment and training for our team members.

Partner with Sun Process Converting for all your die cutting needs and experience the difference that exceptional service and superior products can make for your business. Contact us today to learn more about our die cutting capabilities or to request a quote for your next project!