How to Choose the Right Material Converting Process for Your Component

Original equipment manufacturers (OEMs) often need more than raw material. Adhesives, foams, films, tapes, rubber materials, and other flexible substrates typically begin as rolls or sheets and must be converted into finished components that fit the product, assembly process, and production requirements.

PGC manufactures custom gaskets, seals, spacers, insulators, adhesive-backed parts, and other flexible components based on customer drawings and specifications. The appropriate converting process depends on several factors, including the material, part geometry, dimensional requirements, production quantity, tooling needs, and desired delivery format. These processes support custom components used in medical devices, aerospace and defense equipment, industrial systems, electronics, and other engineered OEM products.

Die Cutting

Die cutting uses custom tooling to create finished components from flexible materials. It is commonly used to manufacture gaskets, seals, spacers, insulators, and other parts with repeatable shapes and features. The process may be suitable when production quantities justify dedicated tooling and the component requires consistent geometry across a production run. Material type, thickness, part dimensions, tolerances, tooling configuration, and order quantity all influence the die-cutting approach used for a project.

Rotary Die Cutting

Rotary die cutting uses cylindrical tooling to continuously process material, often from a roll. This method may be suitable for higher production quantities and components that benefit from continuous processing. Depending on the material construction and part requirements, rotary converting may incorporate operations such as cutting, laminating, kiss cutting, and perforating within the production process. Rotary die cutting may also allow components to be supplied on rolls or liners, which can support handling and placement during assembly. The suitability of rotary converting depends on the material, part geometry, quantity, tooling requirements, and required delivery format.

Adhesive Laminating

Adhesive laminating bonds two or more materials together to create a combined construction. For example, an adhesive may be laminated to foam, rubber, film, or another flexible substrate to create a component that can be installed directly into an assembly. Laminating may be used to support sealing, cushioning, thermal management, insulation, bonding, or assembly requirements.The materials, adhesive compatibility, surface conditions, component function, and application environment should all be considered when determining whether a laminated construction is appropriate.

Skiving

Skiving reduces foam, rubber, or another suitable material to a specified thickness. This process may be used when standard material thicknesses do not align with the dimensional requirements of a component or assembly. Skived materials can be converted into gaskets, seals, cushioning components, spacers, and other parts. The finished material should be evaluated against the dimensional and performance requirements established for the application. Material type, starting thickness, target thickness, surface condition, and required consistency all affect the skiving process.

Kiss Cutting

Kiss cutting cuts through the component material while leaving the release liner intact. This process is commonly used for adhesive-backed gaskets, seals, spacers, and other pressure-sensitive adhesive components. Keeping the liner intact can help organize individual parts, protect the adhesive surface, and make components easier to remove and place during assembly. Kiss-cut parts may be supplied on sheets, strips, or rolls depending on the component, quantity, and assembly requirements.

Flash Cutting

Flash cutting is a digital, tool-free cutting process that does not require a dedicated cutting die. It may be suitable for prototypes, design revisions, material evaluations, and selected lower-volume production requirements. Because dedicated tooling is not required, flash cutting can help reduce initial tooling expense and allow part geometry to be evaluated before moving to another production process. Material type, thickness, part complexity, dimensional requirements, quantity, and edge-quality expectations influence whether flash cutting is appropriate.

What Determines the Appropriate Converting Process?

No single converting method is suitable for every component. Process selection may depend on:

• - Material type and thickness
• - Part geometry and feature size
• - Dimensions and tolerances
• - Adhesive or multi-layer requirements
• - Prototype and production quantities
• - Tooling considerations
• - Inspection requirements
• - Customer assembly methods

In some cases, a component may require more than one converting operation. For example, a material may be laminated before it is die cut, or an adhesive-backed component may be kiss cut and supplied on a liner. Reviewing the complete component and production requirements helps determine which manufacturing approach may be practical.

How PGC Supports Custom Converting Projects

PGC converts materials into custom gaskets, seals, spacers, insulators, adhesive-backed parts, thermal-interface components, and other engineered components for OEM applications. PGC works from customer-provided drawings, specifications, material requirements, quantities, and quality criteria to evaluate manufacturing fit and identify a practical converting approach. Depending on the project, the manufacturing approach may include die cutting, rotary die cutting, laminating, skiving, kiss cutting, flash cutting, or a combination of processes.

Have an active component project? Submit your drawing, application requirements, and estimated quantity to help PGC evaluate manufacturing fit and prepare an accurate quotation.