Die Cutting

About This Helpful Hint

This “Helpful Hint” is intended to explain the advantages and disadvantages of using a roll type product in die cut applications. Knowing about and considering the characteristics listed below during the quoting process can save you a lot of money by heading off potential causes of defects, scrap, complaints and returns.

Considerations

The Material Configurations – Always remember that our vinyl foams are manufactured as tape products with the adhesive exposed. (See Standard Configuration of Foam).

Standard Configuration of Foam
To cover the exposed adhesive for die cutting purposes involves a process we call reverse wrapping (reverse unwinding) the material. During the reverse wrap process what you are actually doing is changing the configuration of the material (see Altered Configuration of Foam). The material will appear to have the paper liner covering the adhesive, but what has actually taken place is that by reverse wrapping the material you have compressed the material onto the shorter, next wrap of liner inside. Also note that there is a loss in yield equal to the amount of paper removed (the circumference of the roll).

Die Cut Facts

Processing the Material – If you decide to reverse wrap tape grade manufactured material, you should consider buying (XR). XR is an easier foam release coating, which lowers the force necessary to break the foam-casting paper bond. This will allow you to unwind the log without stretching or tearing the foam since the foam to casting paper bond created during the manufacturing process is now less than the adhesive paper bond.

Dimensional Gain – If you decide to reverse wrap the material, you need to consider the machine direction effect on the material versus the tolerances involved. Remember the loss in yield from material compression onto the inner layer will show up as gain on the die cut piece once the liner is removed. The pieces will grow because the foam is trying to recover to the original configuration. (Note: The die can be orientated so the largest dimension is cut in the cross machine direction to minimize this problem.).

Minimizing Loss – The most cost effective way to minimize the losses listed above is by ordering the most suited product for your needs. On thinner products, we suggest purchasing longer rolls to reduce the percentage lost. (The length of the roll increases much more rapidly than the circumference). Another solution would be to order transfer wrapped products specially made for die cutting (such as V713). What transfer wrapped means is that we will laminate a newliner on the adhesive side of the material and remove the casting paper. This prevents loss of product yield during processing and dimensional change in the product after die cutting due to reverse wrapping.

Die Cutting vs. Kiss Cutting – In the above suggestion (Minimizing Loss) the product referred to uses a brown, release paper (.006” thick) that we recommend for die cutting thicker products. However, if you’re going to be kiss cutting (not cutting through the carrier) we recommend using our brown release board (.011 thick) (e.g. V717).

Purchase Price vs. Total Cost – The product suggestions in Minimizing Loss and Die Cutting vs. Kiss Cutting require additional lead times and because of the additional operations and materials involved will initially cost more per linear foot. However, buying standard tape grade product and changing the configuration (reverse wrap) will increase your piece price due to yield losses, which is why we recommend that for thicknesses over .188”, you purchase die cut grade products with transferred release paper or board.

The Competition – All material manufactured via a casting process are subject to the above. (Cast products can be identified by the bond between the release liner and foam, which is created during the manufacturing process).