Custom Rotary Die-Cutting Services
At Rathbun, we specialize in custom rotary die-cutting services. We work with a wide range of materials, including foams, films, and tapes, providing precision-cut components to industrial customers nationwide. As an ISO 9001:2015 certified manufacturer and a 3M Preferred Converter, we have decades of experience delivering consistent quality, fast lead times, and helpful service.
Our rotary die-cutting services use high-speed presses to cut materials into custom dimensions with tight tolerances. This method is ideal for large production runs that require superior repeatability and clean, edge-finished products. All die-cut parts are processed in-house at our US facilities and can be delivered in roll form or as individual components, depending on your application.
Our rotary die-cutting services use high-speed presses to cut materials into custom dimensions with tight tolerances. This method is ideal for large production runs that require superior repeatability and clean, edge-finished products. All die-cut parts are processed in-house at our US facilities and can be delivered in roll form or as individual components, depending on your application.
Your Source for High-Volume Precision Die-Cutting Services
If you're looking for rotary die cutting services, Rathbun has you covered. Contact us today to discover how we can deliver custom rotary die-cut solutions tailored to your unique requirements. With proven material expertise and flexible production options, you can rely on Rathbun for top-quality converting servicesRotary die cutting is a high-speed converting method that uses a die and rotary press to cut complex shapes with tight tolerances. The material is fed through a machine, where the die continuously cuts out the desired pattern with precision and consistency. Unlike steel rule dies, rotary die-cutting blades remain stationary during the cutting process, creating consistent and repeatable impressions with single-machined rotary tooling. This process is used for high-volume production due to its speed and repeatable results. Rotary die cutting can also incorporate kiss cutting, through cutting, scoring, and perforating.
Rotary Die Cutting Advantages and Capabilities
Rotary die cutting is a fast, precise, and repeatable process. Its ability to handle tight tolerances and complex dimensions makes it ideal for manufacturers that require consistent and efficient production. Rotary die cutting is used to produce a wide range of custom components, including pressure-sensitive adhesives, thin gaskets, and thin metal foils, among others. While rotary die cutting may incur higher operational costs than other methods, its high-volume capacity, versatility, and efficiency make up for the additional price.Benefits of Rotary Die Cutting
- Tight-tolerance precision for complex die cuts
- High-speed, high-volume production efficiency
- Inline converting options, including kiss cutting, scoring, perforating, and laminating
- Compatibility with pressure-sensitive adhesives, thin foams, gaskets, and metal foils
- Support for materials up to 0.06" thick
- Finished parts delivered loose-cut or in roll form
- Rapid turnaround from prototyping to full production
Available Materials for Custom Rotary Die Cutting
We understand how to cut a wide variety of materials. Our custom rotary die-cutting material capabilities include:- ISOLOSS LS Foams
- Thermally conductive tape
- Thermal interface materials (TIMs)
- Rubber
- Plastics
- And many, many more.
Need Custom Rotary Die Cutting for Your Project?
Rathbun provides precision rotary die-cutting services for foams, adhesive tapes, films, and other specialty materials. From intricate shapes to high-volume production runs, our team can help produce consistent, tight-tolerance components tailored to your application. Tell us about your project requirements to get started.
Start Your Custom Converting ProjectIndustries That Rely on High-Volume Precision Die Cutting
Custom rotary die-cutting services are used throughout virtually every industry. As a preferred 3M™ converter, Rathbun has had the privilege to offer precision die cutting to many sectors:- Medical and healthcare
- Aerospace
- Military and defense
- And many others!
Your Reliable Provider of High-Quality Rotary Die Cutting Services
Rathbun is a trusted converter and distributor of products manufactured by top manufacturers, including Aearo Technologies (previously E-A-R), 3M, and many others. As a family-owned and operated business, we are committed to providing you with dependable, start-to-finish services, innovative products, and exceptional customer service. If custom rotary die-cutting does not work for your production, we also offer:Start Your Custom Rotary Die Cutting Project
Rathbun provides precision rotary die-cutting solutions for tapes, foams, films, adhesives, and other specialty materials. Our team works closely with customers to deliver high-quality, USA-manufactured components tailored to their specifications and production requirements. Whether you need custom shapes, intricate designs, or high-volume production, we're ready to help. Submit your custom converting project to get started, or call us at 510-661-0950 to discuss your application needs.
Rotary Die Cutting FAQs
What is rotary die cutting and when is it the right choice?
Rotary die cutting uses a cylindrical die to continuously cut shapes from product supplied on a roll. It's a highly consistent and repeatable solution for high-volume and high-speed production runs with simple-to-moderate part designs.How does rotary die cutting compare to flatbed die cutting?
Rotary die cutting is faster and more cost-effective for long runs. Flatbed die cutting offers more flexibility for short runs, thicker materials, or more complex shapes. Rathbun offers both, so you can match the process to your material, geometry, volume, and project needs. Learn more about our die cutting services.What materials work with rotary die cutting?
This process is built for flexible thin stock that is roll-fed, generally under 0.060". Rigid and thicker sheets aren't a good match for rotary tooling. If your material falls outside that range, we offer alternative converting methods that may work better.Can rotary die cutting handle kiss-cutting and through cutting in the same pass?
Yes. Rotary tooling can be designed for kiss-cuts, full cuts, score lines, perforations, or a combination of these, depending on the application. Combining functions in one pass reduces handling and improves consistency, which is especially useful for liner-retained or peel-and-stick components. Learn more about our kiss-cutting capabilities.What are typical lead times and minimum order quantities?
Lead times vary depending on material availability and whether existing tooling can be used or a new die needs to be manufactured. Because of setup costs, rotary die cutting works best for established, higher-volume programs, but we support projects from prototyping through full production. Contact us to discuss your timeline.
