Posted by eshuey on | Comments Off on Die Cutting Technologies Explained
When it comes to manufacturing precision adhesive components, gaskets, protective films and specialty materials, selecting the right die cutting technology can have a significant impact on cost, quality, production speed and scalability.
Many manufacturers know they need a die cut component, but determining how that component should be manufactured is often the more difficult decision. Should you use rotary die cutting? Flatbed steel rule dies? Solid steel tooling? Laser cutting? Or would a digital cutting table be the best solution?
The answer depends on your production volume, material characteristics, tolerances, budget, and long-term manufacturing goals.
At TPC Converting, our role isn’t simply to manufacture parts. We work alongside customers to evaluate their application and recommend the die cutting methodology that delivers the best combination of performance, efficiency, and total cost of ownership.
Different Types of Die Cutting
While all die cutting methods produce precision parts, each technology is designed for different production requirements.
Rotary Die Cutting
Rotary die cutting utilizes cylindrical dies mounted on a rotary press to continuously process material as it moves through the machine. This makes rotary die cutting one of the fastest and most efficient manufacturing methods for high-volume production.
In addition to cutting complex shapes, rotary presses can perform multiple converting operations during a single pass, including:
Lamination
Slitting
Sheeting
Scoring
Perforating
Liner changes
Island placement
Pneumatic knock-out
Automated stacking
Because several operations can be completed simultaneously, rotary die cutting minimizes handling, improves consistency, and reduces overall production costs.
Best Applications
Rotary die cutting is ideal for:
High-volume production
Pressure-sensitive adhesive tapes
Protective films
Labels
Medical and industrial components
Continuous roll-to-roll converting
For manufacturers producing thousands of identical parts, rotary die cutting typically offers the lowest cost per part.
Flatbed (Steel Rule) Die Cutting
Flatbed die cutting (often referred to as CNC or steel rule die cutting) uses a flat press equipped with a custom steel rule die to stamp parts from sheet material.
Unlike rotary converting, flatbed presses excel when working with thicker or more rigid materials that may not process efficiently through rotary equipment.
Steel rule tooling also provides an economical solution for medium production volumes or projects that don’t justify investing in rotary tooling.
Best Applications
Flatbed die cutting is commonly used for:
Foam materials
Rubber
Gasket materials
Thick adhesive constructions
Plastic sheets
Silicone
Fabric
Specialty materials
Because tooling costs are generally lower than rotary tooling, flatbed die cutting offers an excellent balance of flexibility and affordability.
Solid Steel Dies
Solid steel dies are precision-machined from hardened steel rather than assembled using steel rule blades.
These dies provide extremely tight tolerances and exceptional repeatability, making them ideal for demanding applications where dimensional accuracy is critical.
Although tooling costs are higher, solid steel dies often deliver longer tool life and superior consistency in high-volume production environments.
Best Applications
Solid steel dies are frequently selected for:
Tight tolerance components
High-precision electronics
Automotive components
Medical devices
Long production runs
Complex geometries
When quality requirements leave little room for variation, solid steel tooling often becomes the preferred solution.
Laser & Knife Cutting
Unlike traditional die cutting methods, laser and digital cutting systems eliminate the need for physical tooling altogether.
At TPC Converting, our knife cutting table allows us to quickly produce:
Prototype parts
Samples
Low-volume production
Design iterations
Custom one-off components
The knife cutting tables can:
Perform total cuts or kiss cuts on linered materials
Cut sheet materials
Produce gasket geometries
Punch holes
Score and fold materials
Because no tooling must be manufactured, customers can validate designs before committing to production tooling.
Best Applications
Digital cutting is ideal for:
Engineering validation
Product development
Prototype evaluation
Small production runs
Frequent design changes
For many projects, digital cutting serves as the bridge between concept and full-scale production.
This is why engineering consultation is such an important part of the process.
More Than Cutting: Complete Converting Capabilities
One advantage of partnering with TPC Converting is that we offer far more than die cutting alone.
Our in-house converting capabilities include:
Lamination
Slitting
Sheeting
Perforating
Scoring
Liner changes
Island placement
Stacking
Custom packaging solutions
By performing multiple value-added operations under one roof, we help customers reduce supplier complexity, improve quality control, and shorten lead times.
Materials We Commonly Convert
Our die cutting technologies allow us to process an extensive range of materials, including:
Pressure-sensitive adhesives
Foam tapes
3M™ VHB™ tapes
Protective films
Silicone
Rubber
Gasket materials
UHMW polyethylene
Fabric
Label stock
Plastics
Non-woven materials
Abrasive materials
Specialty engineered materials
Whether the application requires thin adhesive films or thick gasket materials, we work with customers to determine the best manufacturing approach.
Industries We Serve
Our converting expertise supports manufacturers across a wide range of industries, including:
Automotive – Precision gaskets, insulation, vibration dampening, and sealing components for Tier 1 and Tier 2 suppliers.
Appliances – Noise reduction materials, foam gaskets, seals, and assembly components that improve product performance.
Assembly & Manufacturing – Die cut adhesive solutions that streamline assembly processes while reducing labor and improving consistency.
Sign & Graphics – Precision-cut materials for dimensional signage, point-of-purchase displays, labels, and promotional graphics.
Why Work with TPC Converting?
With more than 55 years of converting experience, TPC Converting helps manufacturers evaluate every aspect of their project to determine the most efficient and cost-effective production method. Whether that means rotary die cutting for high-volume production, flatbed steel rule dies for thicker materials, solid steel tooling for precision components, or digital cutting for rapid prototyping, our team provides guidance based on your manufacturing goals.
From concept and prototyping through full-scale production, we help customers optimize their converting process.
Looking for the right die cutting solution?Contact TPC Converting to discuss your application with our converting specialists and discover which die cutting technology is best suited for your project.
Posted by TPC Converting on | Comments Off on A Guide to Slitting Techniques: Shear, Crush, Razor, and Score Slitting
Precision slitting is a key step in the converting process for flexible materials. Whether you’re working with films, foams, papers, foils, or pressure‑sensitive adhesive tapes, the slitting method used can directly impact edge quality, tolerances, production speed and overall performance in downstream applications.
At TPC Converting, we specialize in precision slitting and rewinding services that transform large master rolls into custom widths tailored to your exact application. With more than 55 years of converting experience, our team carefully selects and fine‑tunes slitting techniques based on how each material interacts with blades, equipment, and process parameters.
Below, we break down the most common converting slitting techniques, including razor slitting, crush cut slitting, shear slitting, and score slitting, and explain when each method is most effective.
What is Slitting?
Slitting is the process of cutting large rolls of flexible material into narrower rolls or strips that are easier to handle and ready for manufacturing, packaging, or assembly. This process is commonly paired with rewinding, which transfers the slit material onto smaller, more manageable rolls.
Passing the material through a strategically arranged set of blades
Cutting the material to precise, non‑standard widths with tight tolerances
Rewinding finished rolls for transport, storage or further converting
We also offer lathe slitting, which slices a master roll into narrower widths without unwinding. This method is ideal for select applications that require rigid control and minimal material handling.
Our versatile slitting capabilities support a wide range of materials, including foam, paper, plastic films, foils, and tapes, making slitting a foundational service across many industrial converting operations.
Different Slitting Techniques
Choosing the correct slitting method depends on the material type, thickness, desired edge quality, production speed and final application requirements. Below is an overview of the most common slitting techniques used in converting.
Razor Slitting
Razor slitting uses sharp razor blades to cleanly cut thin, flexible materials. This technique is used for applications where precision, minimal material distortion and clean edges are required.
Razor slitting is commonly used for:
Plastic films
Foils
Lightweight laminates
Fragile or delicate materials
Because razor slitting creates minimal stress on the material, it is frequently preferred in packaging, electronics, and medical converting applications where edge quality and waste reduction matter most.
Types of Razor Slitting
Razor-in-Air (Top Razor Slitting)
Razor‑in‑air slitting positions the razor blade above the material, cutting it without any additional backing or support beneath the web. Because the blade makes direct contact with the material alone, this method is best suited for slower speed converting operations and applications that require a lighter cutting approach. Razor‑in‑air slitting is a cost-effectiveoption due to its simple tooling, straightforward setup and ease of blade maintenance. It is most commonly used for thin films, foils and other fragile materials to maintainedge integrity while minimizing equipment complexity.
Razor-in-Groove (Bottom Razor Slitting)
Razor‑in‑groove slitting cuts the material against a grooved support roll, providing added stability to the razor blade during the cutting process. This additionalsupport allows the material to remain more controlled as it passes through the blade, making the method well suited for higher‑speed production environments and more demanding applications. By stabilizing the web during slitting, the grooved roll helps reduce edge defects and improves overall cut consistency. Razor‑in‑groove slitting is often selected when tighter tolerances,increased throughputand improved edge quality are required.
Crush Cut Slitting
Crush cut slitting works by pressing a circular knife against a hardened anvil roll, effectively crushing and cutting the material. This technique is often used for softer, compressible materials that respond better to forceful separation. Crush cutting doesn’t dull the blade, which results in much a longer blade life and consistent edges throughout a run.
Crush cut slitting is ideal for:
Rubber materials
Foams
Certain pressure‑sensitive tapes
Other soft or spongy substrates
While crush cutting is efficient and economical, it may produce a slightly rougher edge compared to shear or razor slitting. For applications where edge appearance is not critical, crush cut slitting offers a simple and effective converting solution.
Shear Slitting
Shear slitting uses a male and female circular knife arrangement that creates a scissor‑like cutting action. This method delivers exceptional edge quality while supporting high‑speed production.
Shear slitting is well suited for:
Paper and paperboard
Laminates
Plastic films and foils
Textiles and specialty materials
Because shear slitting balances speed with precision, it is often selected for demanding applications requiring tight tolerances and superior edge finishes.
Score Slitting
Score slitting creates a controlled indentation or score line using a blunt blade or scoring wheel. Instead of cutting fully through the material, this method weakens specific areas to allow for precise folding.
Score slitting is commonly used in:
Corrugated sheets
Cartons and boxes
Folding packaging components
This technique supports consistent folds and clean bends during packaging production.
How TPC Converting Delivers Precision Slitting Solutions
At TPC Converting, no two slitting jobs are treated the same. Our experienced team fine‑tunes each setup based on material behavior, performance requirements and downstream needs.
With capabilities that include precision slitting and rewinding, cutting, spooling, adhesive laminating and coating, printing, and finishing, we provide custom converting solutions across a wide range of industries.
Our ISO 9001:2015 and IATF certifications reflect our ongoing commitment to quality, consistency, and customer satisfaction.
Partner with TPC Converting for Precision Slitting Services
Whether your application requires razor slitting for delicate films or shear slitting for high‑volume production, TPC Converting has the expertise and equipment to deliver reliable results.
Posted by TPC Converting on | Comments Off on What Is Corona Treatment and How Does It Improve Adhesion in Converting?
Corona treatment is a high‑frequency surface treatment process used in converting to increase surface energy and improve adhesion of inks, coatings and adhesives on low‑energy materials such as rubbers and foams. By modifying only the outermost surface of a substrate, corona treatment enables stronger, more consistent bonding without altering material performance.
At TPC Converting, we provide high frequency, wide‑web corona treatment converting services; a capability offered by only a small number of converters in the United States.
How Corona Treatment Works
Rather than focusing on the basic definition, it’s more helpful to understand what corona treatment actually does at the material level and why it is so effective in converting applications.
Corona treatment works by using high‑frequency electrical energy to modify only the outermost surface of a substrate. This controlled energy alters the surface chemistry by creating additional active bonding sites, allowing inks, coatings, and adhesives to interact more effectively with the material.
Importantly, corona treatment:
Affects only the surface
Does not change thickness, strength, or flexibility
Prepares the material specifically for downstream converting processes
The result is a surface that is more receptive to bonding, enabling stronger adhesion, more consistent print quality, and improved overall product performance, especially on materials that are otherwise difficult to bond.
Why Surface Energy Matters in Adhesion and Converting
Surface energy directly impacts how well a material bonds to inks or adhesives.
Low Surface Energy Materials
Liquids bead up instead of spreading
Adhesives struggle to wet-out on the surface
Bonds are weaker and less consistent
High Surface Energy Materials
Liquids spread evenly
Stronger molecular attraction
Improved adhesion and durability
Most rubbers, foams, and polymer‑based materials naturally have low surface energy, making them difficult to print or bond without surface treatment. Corona treatment increases surface energy so adhesives and inks can perform as designed.
Types of Corona Treatment Used in Converting
There are multiple surface‑treatment methods used in converting, including flame treatment, plasma treatment, chemical priming, and corona discharge treatment. Among these, corona discharge treatmentis the most widely used in roll‑to‑roll converting due to its speed, consistency, and process control.
High‑frequency corona treatment is the most controlled and precise form of corona treatment. It allows converters to fine‑tune treatment levels for uniform surface energy across the entire web—especially critical for demanding adhesive and printing applications.
TPC Converting offers high‑frequency corona treatment converting services for materials supplied in sheet or roll format. Our process introduces ionized gases to the material surface and applies controlled voltage to modify surface energy with precision and repeatability.
Key Benefits of TPC’s Corona Treatment Capabilities
Wide‑web corona treatment up to 62 inches Allows us to corona treat most extruded or coated substrates without secondary slitting, reducing handling, cost and lead time.
Inline converting integration Corona treatment is performed as part of our converting workflow, ensuring surface preparation is optimized for downstream adhesive or printing processes.
Adhesive and ink compatibility We corona treat materials intended for both adhesive bonding and printing applications.
Dyne level testing After corona treatment, we can test the dyne level of your material for a repeatable process.
TPC performs corona treatment every day, making it a core converting capability rather than a limited specialty service.
Materials Commonly Corona Treated at TPC Converting
Corona treatment is especially effective for materials with inherently low surface energy. At TPC Converting, we most commonly corona treat:
Rubbers
Foams
Polymer substrates
Extruded materials
Coated substrates
Rubbers and foams are among the most challenging materials to bond due to their low surface energy. Corona treatment transforms these surfaces into bond‑ready substrates without affecting mechanical performance.
Why Choose TPC Converting for Corona Treatment Services?
If your application involves difficult‑to‑bond materials, materials with low dyne levels, unreliable adhesion, or inconsistent print quality, corona treatment is essential.
TPC Converting combines:
High‑frequency corona treatment technology
Wide‑web capability up to 62 inches
Daily production experience
Dyne level testing
Deep expertise in adhesive and ink‑based converting
This allows us to deliver consistent, high‑quality surface treatment that improves adhesion and expands what’s possible with challenging materials.
Need Corona Treatment for Your Next Converting Project?
Contact TPC Converting to discuss your material, application, and surface‑energy requirements. Our corona treatment services help ensure your adhesives and inks perform exactly as intended.
