advanced die-cutting
High-speed rotary die-cutting, advanced flatbed die-cutting, and inline ultrasonic welding, with inline and offline measurement capabilities. Additional capabilities include robotic part handling for automated inspection and packing, inline vision systems for 100% part inspection, and next generation rotary presses with a closed-loop automated adjustment system to identify tolerance and self-adjust.
Advanced Die-cutting & manufacturing processes
Our advanced manufacturing and conversion facility enable the production of a vast range of die-cut components and die-cut materials including pressure sensitive adhesive tape and advanced flexible materials with customised liner configurations and presentation formats.
efficient manufacturing
Our advanced manufacturing capabilities collectively contribute to improved efficiency, higher quality products, reduced waste, and increased automation in the production process.
These capabilities are particularly beneficial in industries that require precision, customisation, and high-speed production. These technologies align with the principles of Industry 4.0 and the pursuit of smarter, more efficient manufacturing processes.
- Ultra-fast processing speeds up to 150 metres per min and up to 1.5 million parts per hour
- 100 tonne, 2m x 1.5m cutting bed, multi-reel fed
- Ability to configure complex multi-layer components using a customised presentation and format to improve productivity during product assembly
- Automated pick and place for packing and component placement
- Advanced robotics for assembly and automated packing.
Advanced manufacturing capabilities
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HIGH SPEED ROTARY DIE-CUTTING High-speed rotary die-cutting is a process where a rotary die (a cylindrical tool with sharp cutting edges) is used to cut, score, or perforate materials as they pass through a press. This method is particularly efficient for high-volume production of items like labels, adhesive pads, gaskets, and packaging materials. |
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advanced flatbed die-cutting Advanced flatbed die-cutting is a process where a flatbed press equipped with precision steel rule dies is used to cut, crease, or emboss materials. This process is versatile and can be used to cut large shapes and designs from multiple material types, making it suitable for NVH foam and large area masking applications. |
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inline ultrasonic welding Inline ultrasonic welding is a technique that uses high-frequency vibrations to create a bond between materials, often plastics. It's used for joining components without the need for adhesives, solvents, or heat. |
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Measurement Capabilities (Inline & Offline) Inline and offline measurement capabilities involve using various sensors, scanners, and measurement tools to assess the accuracy, dimensions, and quality of manufactured parts. These measurements can be done in real-time during production (inline) or after the parts are produced (offline). |
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Robotic Part handling for Inspection & Packing Robotic part handling involves using robots to manipulate, inspect, and pack parts. Automated robotic systems can efficiently perform tasks like sorting, inspection, and packaging of manufactured components. |
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Inline Vision System for 100% Part Inspection Inline vision systems use cameras and image processing to inspect parts as they move through the production process. These systems can quickly identify defects, inconsistencies, or deviations from specifications. |
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Next Generation Rotary Presses with Automated Adjustment Next-generation rotary presses incorporate advanced automation and closed-loop control systems. These presses can identify deviations from specified tolerances and automatically adjust parameters to maintain accuracy. |
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Die-cutting parameters
Rotary Parameters
- Part size up to 600mm wide x 1200mm length
- Running speed up to 150 m/min +
- Cutting tolerance up to +/- 50μ
Flat Bed Parameters
- Part size up to 2000mm wide x 1500mm length
- Running speed up to 120 m/min +
- Cutting tolerance up to +/- 1mm
Case study in action
Gasket for injection moulded vehicle instrument cluster
challenge
Improve an established adhesive gasket application for bonding an a-surface component to a vehicle instrument cluster for high-volume manufacturing for a leading injection moulder.
solution
Using a unique adhesive product to effectively block light transfer between instrument light displays. Incorporating design features to enhancing the gasket application into concave-shaped components, while integrating finger-lift tabs to prevent contamination during application, ensuring optimal performance and longevity.
outcome
An improved application process and increased surface contact of adhesive to component with overall enhanced safety and product performance of the vehicle instrument cluster.