Die-Cutting | ABI Tape Services

Die-Cutting - ABI Tape Services
Die-cutting or punching is a fabrication process used to obtain customized shapes (ShapeRite). In our case these shapes are cut from tape. The options are endless and the process is suitable for a wide range of materials.

You have a clear understanding of your production process and we understand our die-cut process. To produce a shape that fits your semi-finished or final product is relatively easy. Over the years we have learned that the real challenge is in how to integrate applying these shapes into your production process. That is why we took this one step further and also offer semi- or fully automated dispenser solutions.

Your Input:

For the shape, we do need a technical drawing. Preferably in a format that can easily be modified to experiment with different cuts that will fit your specific needs.

Additionally, we need your material requirements, which should include the main purpose / function of the shape onto your material. With over 300 different tapes, we can help you find the right tape material for your specific application.  

Optionally, for the application process, we would like to understand the steps of your production process before and after the application, as well as the workspace situation. This way we can propose several options for you to see what works best for your production process.

Our Die-cut Technologies:

ABI Tape deploys different technologies to produce your custom-designed shapes:


Rotary die-cut

A very well-known technology is precision rotary die-cutting. This type of die-cutting uses a cylindrical die-cut knife that pressures the material against a counter roll. The die-cut knife and counter roll are rotating in opposite directions, which makes the web run through the cutting station. The counter roll serves as a surface against which the die-cut tool performs the cut. This technology is particularly efficient for smaller size shapes (up to 30 cm).

Fixed vs flexible cutting tools

ABI Tape offers choice between two kinds of rotary die-cut tools: flexible and fixed. The choice depends on the trade off between production volume, cost of the die, lead time to make the tool and run speeds with the tool.

  • Fixed cutting tools:  the most significant benefit of fixed rotary cutting is the longevity of the tools. Fixed die-cut tools last longer than flexible tools, which makes them the go-to solution for large production runs. Moreover, fixed tools are suited for production runs with a higher machine speed. These tools are made of stainless steel and it takes significant more time to produce (3 to 5 weeks). The cost for these tools are a multi factor of the flexible tools.
  • Flexible cutting tools, on the other hand, wear down faster and are restricted by a lower production speed compared to their fixed counterpart. These tools are made of aluminum and lead time to produce is typically within a week. One also need a magnetic tool to mount the flex tool onto the rotary die-cut. Due to their relatively low manufacturing cost of the die-cut tool, they can be easily replaced when damaged with little downtime.
Depending on the specific details for your project, our team will help you decide which type of die-cut tool is recommended for your product.

Laser die-cut

Laser die-cut machines deploy a high-speed laser to cut through the adhesive material. Unlike the rotary technology, there is no mechanical knife that makes contact with our tape material.

The direction/magnitude of the laser beam is driven by the digital drawing of the shape / part provided. Unlike the rotary technology, it is easier to experiment / customize the design to see an immediate result and at virtually no cost. In addition, there is no initial investment for the production of the mechanical knife, nor long lead times.

In short, the product development costs / lead time is favorable. The run time is generally slower than a rotary but the width restrictions of the rotary have a negative impact on the output.  This technology is particularly efficient for larger size shapes (30 cm and up).



Flatbed cut

Flatbed cut machines deploy a mechanical knife to cut through the adhesive material. This technology is only used for very large size (in excess of 1 meter) shapes.

There is costs and time to develop the cutting tool. One can sharpen the knives to extend the longevity of the tool. The major restriction is slow production speed compared to the other technologies. These tools are made of aluminum.
Types of cut:

Full cut

As the name suggests, these type of cuts go straight through the adhesive material layer and eventually the backing material layer in case a liner is used.

Kiss cut

With this type of cut, the cut does not go completely through the tape material, only partially. One also uses this term, if the adhesive material has liner. The cut will go through the tape material, but not through the liner.

Perforation cut

Technique that is used to hold the die-cut shape in place by a sequence of small holes. Each separate part can be easily removed from the web by ripping the material alongst the perforation line. Products with perforations are offered with or without liner. Also the pattern of cut – non cut is variable.

Our output:

There are several delivery formats possible for die-cut products. Our clients have the option to receive the products in roll format or on sheets. In roll format, the client still has the possibility to choose for a liner or not. Die-cuts on sheets are always on a liner.



With or without liner

Our Samples:

Upon agreement of the technical drawing, our graphic center produces samples on a sheet with a graphic plotting machine. These samples will be sent to the client’s production plant for a fitting test. During the fitting test, the samples are applied. If modifications are required, ABI Tape will modify the technical drawing and plot new samples until you are satisfied.

For every new project, ABI Tape will offer samples so that the client can organize a fitting test prior to serial production. By doing so, the client has the possibility to see our products in real life for their application without ordering large quantities. In case modifications are needed, ABI Tape will act quickly and modify the initial design.