With over 75 years of experience, Gleicher Manufacturing is a family run converting operation out of New Jersey. Our custom die cutting service converts raw tape, foam, film, rubber, and gasket stock into finished components built to your print.

Most converters simply take your spec and cut it but we take it a step further to ensure you receive the best possible results. Our engineers speak with you to understand your application before anything goes into production. With 3 generations of experience in the industry, we know that the material you sourced on a distributor's website may not be the material that is best suited to your chosen application. That kind of mistake is costly and adds up in scrap, rework, and warranty returns.

Die cutting methods we offer

Three die cutting methods are available and job approval helps us decide which one to run:

1. Flatbed die cutting: This process uses a steel rule die on a flat platen with a hydraulic press. The substrate is then placed on the bed and the die head presses down to cut. This method of die cutting is suited to thicker materials as well as large-format sheets. It is usually used for prototyping, short runs and orders that range from a few hundred to low thousands.
2. Rotary die cutter: This method feeds material through a cylindrical die that spins Due to its continuous process rather than individual press cuts, it maintains a tighter tolerance over long runs. When it comes to high volumes, hundreds of thousands to millions, rotary is the preferred option. It is important to note that kiss cutting is a variation of this process in which the die cuts through the face stock and adhesive later but stops at the release liner. This is essential when it comes to peel-and-stick products, notably those used in assembly or on factory lines.
3. Laser Cutting: This process uses a concentrated beam to cut without any physical contact, melting or vaporizing material. There is no tooling required, therefore no dies to produce or wear out. This is effective for complex geometries that are difficult to achieve with traditional methods. Learn more about what we do on our laser cutting service page.

Materials we die cut

As a 3M™ Preferred Converter, we convert a range of 3M™ materials including, transfer tapes, VHB structural tapes, double-coated tapes, and specialty films. We also cut materials from other manufacturers including:

• Pressure-sensitive adhesive tapes
• Open-cell and closed cell foams: polyethylene, polyurethane, silicone
• Films: Kapton, Mylar, PTFE, polyester
• Rubber and silicone sheet stock
• Die cut gaskets and seals
• Hook and loop fasteners
• Thermal management materials
• EMI/RFI shielding
• Plastic films and laminates

A large portion of our work involves multi-layer constructions such as adhesive laminated to foam, then bonded to a film carrier. We handle all laminating in-house. See our industrial laminating service. If you are working with master rolls that need to be converted to specific widths, this is covered under our slitting and rewinding services.

Industries we serve

Custom die cutting produces parts specific to an application across industries. That's the whole point. Current sectors we supply include:

• Aerospace: Adhesive tapes, thermal insulation, gaskets for airframe assembly
• Medical devices: Biocompatible films, diagnostic strips, adhesives for wearables. Our white room die cutting can handle these.
• Electronics: EMI shielding, thermal pads, display mounting tapes, kiss-cut protective films
• Transportation: Vibration-dampening foams, sealing gaskets, trim attachment
• Telecom: Cable wraps, weatherproofing gaskets, antenna attachments
• Military and defense: Mil-spec adhesive parts, ruggedized seals
• Consumer products: Mounting tapes, protection films, cosmetic components

From prototype to production

We provide a hands-on service and the typical point of contact begins with a phone call or detail email, not a purchase order. For example, an engineer is trying to solve a specific issue such as sealing, insulating or dampening. They may have done their research and often come with a material in mind. Sometimes it is the right choice. But just as often, the material will fail down the line because of factors that were not accounted for such as thermal cycling or surface energy of the substrate.

That's where we come in.

The process is:

1. Design consultation: Take a look at your prints, examine your application, run down your working environment. If there's a problem with your material choice, we flag it and suggest a suitable alternative.
2. Prototyping: We cut samples on the laser or flatbed with rapid turnaround. You will then receive parts for true application testing.
3. Tooling: Once design has been finalized, we manufacture steel rule or rotary tooling matched to your production volume and tolerance requirements.
4. Production: All runs are controlled using statistical process control or SPC. With inspections documented at every stage of the process. We scale from small batches to high-volume production that ranges from hundreds to millions of parts.
   
   

Why choose Gleicher for custom die cutting

We are proud to be a third-generation family business that specializes in converting and as a 3M™ Preferred Converter we have direct access to 3M™ labs and engineering support that most converters do not have.

But credentials are just that. Credentials. The real difference is how we do business. Your engineer calls us with an application spec and before we offer a price on that spec, we ask questions about the application. Where will this part be installed? What temperature ranges? What substrates? What application life is anticipated? Often those questions point the customer towards a more suitable product that will outperform and outlast in the field.

We might not be the lowest price on your quote comparison sheet, but we will be the one that saves you money on rejects, rework, and failures in the field.

Supporting capabilities:

• White room converting
• SPC documented manufacturing processes
• Precision tolerances to +/- 0.005 inches
• Fast turnaround on prototyping and production
• Any quantity from prototype samples to large production runs

Frequently asked questions

What is custom die cutting?

Custom die cutting refers to the process of using a purpose-built tool to cut materials into precise and finished shapes. The die is engineered to match your geometry to ensure consistency across every piece. It is used to convert sheet or roll materials such as adhesive tapes, foams, rubber, and gasket stock, into components that are ready for application or assembly.

What materials can be die cut?

The majority of flexible and semi-rigid materials can be die cut. This includes adhesive tapes, foams, films, rubber, silicone, gasket materials, hook and loop. It is important to note that the material thickness factors into choosing the right cutting method.

What is the difference between flatbed and rotary die cutting?

Flatbed die cutting presses a steel rule die into material on a flat surface and is better for lower volumes and thicker materials. Rotary die cutting feeds material through a cylindrical die at a greater speed which is better for high-volume production, while kiss cutting operations cut through the top layer without cutting all the way through the liner.

How tight are the tolerances on die cut parts?

Standard precision die cutting holds +/- 0.015 to 0.030 inches while rotary die cutting with matched tooling can hold +/- 0.005 inches.

What is the typical lead time for custom die cut parts?

Prototypes can ship in days when laser cutting is used. Production runs with existing tooling can take 1-2 weeks. New tooling adds time depending on the complexity however all scheduling is locked in at the quoting stage.

Talk to us about your project. Call 888-818-5798 or request a quote online. We will review your application, suggest a suitable method and material, and send sample parts to you promptly.