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Die cutting size introduces limitations based on material type, cutting method, and tolerances and adapting to these constraints is critical to ensuring high-quality results.
This guide covers and includes:
- Key constraints in die cutting various materials;
- A comparison of rotary and flatbed, the most common processes used;
- An in-depth material chart that accounts for tolerance differences; and
- A guide to using this information when consulting with vendors
Die Cutting Size Chart: Materials and Size Limitations
Selecting the right die cutting method depends on the material type and the required dimensions. The following chart outlines die cutting size capabilities for common materials:
| Material | Max Sheet Size (Flatbed) | Max Roll Width (Rotary) | Thickness Limit (Flatbed) | Thickness Limit (Rotary) |
| Paper & Cardboard | 40″ x 96″ | 16″ (slit from jumbo) | Up to 0.5″ | Up to 0.015″ |
| Plastic Films | 36″ x 72″ | 16″ | Up to 0.25″ | Up to 0.015″ |
| Rubber & Foam | 40″ x 96″ | 16″ | Up to 0.5″ | Up to 0.015″ |
| Adhesives & Labels | 24″ x 36″ | 16″ | Up to 0.125″ | Up to 0.015″ |
| Metal Foils | 24″ x 36″ | 16″ | Up to 0.1″ | Up to 0.015″ |
| Gaskets & Composites | 40″ x 96″ | N/A | Up to 0.5″ | N/A |
Key Die Cutting Size Constraints
Die cutting is subject to several limitations that affect the maximum and minimum size of the parts that can be produced, specifically: machine capabilities, material properties, and tolerance requirements.
Factors Affecting Die Cutting Size
| Factor | Impact on Die Cutting Size |
| Machine Bed Size | Limits max sheet size for flatbed cutting |
| Roll Width | Determines max width for rotary cutting |
| Material Type | Some materials stretch/deform, affecting precision |
| Tolerance Levels | Dictates final part accuracy in manufacturing |
Additional factors include the complexity of the design and cutting die wear over time. Sharp dies can produce highly precise cuts, while dull dies may lead to deviations, affecting tolerances. The temperature and humidity conditions in a production environment can also influence material behavior, especially with adhesives and foams.
Material Behavior During Cutting
Different materials react uniquely to the cutting process, which affects the quality and precision of the final product. To avoid issues with quality and precision, thinner materials or special dies may be used, but in general die cutters will adjust dimensions first, where possible. Below are some key material impacts on die cutting:
- Paper & Cardboard: These materials cut cleanly but can fray at the edges if the die is dull. Paper thickness affects tear resistance, requiring careful consideration of force applied.
- Plastic Films: Films are prone to stretching, which can lead to dimensional inaccuracies. Rotary cutting is preferred for thin plastics to minimize distortion.
- Rubber & Foam: These materials compress during cutting, which can cause rebound effects leading to slight dimensional changes. Proper die clearance is needed to compensate for this.
- Adhesives & Labels: Adhesive-backed materials may experience edge residue buildup on cutting dies, necessitating periodic cleaning to maintain precision.
- Metal Foils: Thin metal foils require high-pressure flatbed cutting to prevent warping or wrinkling. Too much force can cause micro-tears in the material.
- Gaskets & Composites: Composite materials can have multiple layers with different hardness levels, requiring precision cutting to avoid delamination.
Rotary vs. Flatbed Die Cutting: A Comparison
The type of die cutting process used also significantly impacts the maximum part size and material thickness that can be handled.
Rotary Die Cutting
- Best for: High-volume production of flexible materials
- Max Roll Width: 16 inches (can be slit from larger jumbos)
- Max Material Thickness: Up to 0.015 inches
- Common Uses: Labels, thin foams, films, and adhesive-backed components
- Advantages: Faster speeds, continuous operation, cost-effective for high-volume runs
- Disadvantages: Limited to thin, flexible materials
Flatbed Die Cutting
- Best for: Thicker, rigid materials requiring precise cuts
- Max Sheet Size: 40” x 96”
- Max Material Thickness: Up to 0.5 inches
- Common Uses: Gaskets, rubber seals, composites, and thick plastics
- Advantages: Greater versatility, ability to cut rigid and thick materials, precise custom shapes
- Disadvantages: Slower than rotary die cutting, may have higher setup costs
Rotary vs. Flatbed Die Cutting Comparison
| Feature | Rotary Die Cutting | Flatbed Die Cutting |
| Max Width | 16 inches | 40 inches |
| Max Thickness | 0.015 inches | 0.5 inches |
| Cutting Method | Roll-fed process | Sheet-fed process |
| Material Type | Flexible, thin materials | Rigid, thick materials |
| Ideal for | High-speed, high-volume production | Custom shapes and thick materials |
Industry-Specific Die Cutting Size Needs
Each industry has unique requirements for die cut components, depending on material properties, required tolerances, and final product applications. Choosing the right die cutting process ensures efficient production, cost savings, and product consistency.
| Industry | Commonly Used Materials | Preferred Cutting Method | Size Considerations |
| Automotive | Rubber, foam, gaskets, acoustic insulation | Flatbed | Large sheets needed for seals, interior insulation, and under-hood components |
| Medical | Adhesive-backed materials, thin plastics, foams | Rotary | Small, precise cuts for wound dressings, medical patches, and diagnostic strips |
| Electronics | EMI shielding films, conductive foils, tapes | Rotary | Thin layers requiring tight tolerances for circuit protection and heat dissipation |
| Aerospace | Lightweight composites, high-temp-resistant foams | Flatbed | Large panel cutting for thermal insulation and vibration dampening |
Automotive Sector
The automotive sector heavily relies on die cutting for gaskets, seals, vibration dampeners, and acoustic insulation. Flatbed die cutting is preferred due to the need for precision cuts in thicker rubber and foam sheets. For example, automotive door seals require tight tolerances to prevent air or water leaks.
Industry Needs:
- Large component sizes require wider die cutting beds.
- High durability requirements demand consistent tolerance levels.
- Materials such as neoprene rubber and EPDM foam need clean cuts to maintain sealing properties.
Medical Sector
Medical manufacturers require high-precision, contamination-free cutting for adhesive-backed dressings, disposable face shields, and diagnostic test strips. Rotary die cutting is ideal for this industry because it allows for continuous high-speed production of small, intricate parts.
Industry Needs:
- Many materials used in medical devices are thin and delicate, requiring careful tension control.
- Rotary die cutting is ideal for high-volume manufacturing of adhesive bandages and wearable sensors.
Electronics Industry
The electronics sector requires thin, precision-cut components such as EMI shielding films, conductive tapes, and thermal management materials. Rotary die cutting is favored due to its ability to handle thin foils and layered materials without deformation.
Industry Needs:
- Many components must fit into compact spaces within electronic devices, requiring micron-level precision.
- Materials such as graphite-based heat spreaders and conductive foils are prone to stretching, requiring precise die cutting tolerances.
- Consistency is essential for mass production of smartphone and PCB components.
Aerospace Industry
Aerospace applications often require large, lightweight, and heat-resistant materials for insulation panels, composite gaskets, and vibration-dampening foams. Flatbed die cutting is best suited for these applications because it can handle rigid, thick composite sheets with high accuracy.
Industry Needs:
- Components must withstand extreme temperatures and pressure changes.
- Materials such as fiberglass-reinforced foams and Nomex honeycomb panels require high-precision cutting without fraying.
- Large sheets are often die-cut into custom panel shapes for aircraft interiors and insulation layers.
Sourcing the Right Die Cutting Supplier
Choosing the right supplier is critical for ensuring part quality, efficient production, and cost-effectiveness. Manufacturers need to know the following capabilities to ensure that the supplier they choose can meet their needs for component production. Below is a sample of our capabilities to use as a reference point.
Colvin-Friedman Die Cutting Capabilities
| Category | Flatbed Die Cutting | Rotary Die Cutting |
| Maximum Product Width | 40 inches | 16 inches (can slit larger jumbos) |
| Maximum Product Thickness | 0.5 inches (material dependent) | 0.015 inches (flexibility based on material) |
| Tolerance Level | ±0.010 inches (material dependent) | ±0.005 inches |
| Maximum Production Capacity | 2,000 – 4,000 parts/hour (size dependent) | 40,000 units/hour (size dependent) |
| Average Lead Time | 3 weeks | 3 weeks |
Other key capabilities to note when selecting a die cutting vendor for integration into a production pipeline include:
- Tolerance guarantees for different materials
- Experience working with the materials in question
- Ability to integrate within inventory management systems (IMS)
- Quality control measures
Ensuring the Right Fit for Your Die Cutting Needs
Die cutting size limitations impact everything from material choice to final part performance. Working with an experienced supplier ensures that material sheets are maximized, tolerances are maintained and final components precisely match the given design, even after thousands of units in production.
To learn more about how sizing affects component production, fill out the brief contact form to get in touch with the experts at Colvin-Friedman, or call Vice President Josh Rodman at (707) 769-4488.