Custom Die Cutting Services
XC Machining provides custom die cutting for US product teams. We turn foam, rubber, gasket sheet, adhesive films and thin metal foils into precise shapes. Flatbed steel rule dies hold ±0.25 mm on material up to 25 mm thick. Rotary dies hold ±0.05 to ±0.13 mm at high speed. Steel rule tooling is ready in 1 to 3 business days, and first parts ship in 3 to 7 business days. Kiss cutting, through cutting, perforation and scoring are all available.
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What Is Custom Die Cutting at XC?
Die cutting presses a shaped steel blade, the die, against flat material to cut a precise shape. It needs no heat. XC cuts gaskets, seals, foam pads, adhesive labels, insulation sheets and EMI shields this way. Tolerance runs from ±0.05 mm on rotary dies to ±0.25 mm on flatbed steel rule dies. Volumes run from 100 to more than 500,000 parts.
Support From Material Choice to Inspection
Packaging, electronics, automotive and manufacturing teams order die-cut parts from XC. Our engineers help with material selection and stay on the job through final inspection. US customers get that support at a competitive price.
Why Choose XC for Die Cutting
XC offers four die routes. Flatbed steel rule gives tooling in 1 to 3 days and parts in 3 to 7. Rotary runs high-volume continuous feed at ±0.05 mm. Kiss cutting handles adhesive parts, and matched metal dies reach ±0.025 mm. DFM review takes 12 hours. The factory is ISO 9001:2015 certified.
Each flatbed die is a laser-cut plywood board with a custom-bent steel rule blade, set to your part profile at ±0.25 mm. Tooling costs $50 to $500. That keeps prototype runs of 100 parts and medium runs of 50,000 parts affordable.
The die cuts through the adhesive layer and stops at the release liner. Inline inspection checks that the liner stays intact. PSA gaskets, foam tape pads and peel-and-apply insulation parts reach assembly with the adhesive still protected.
Upload a DXF or PDF. Engineers check minimum feature size, bridge width, corner radii, material and adhesive system. They also recommend a die type based on volume, tolerance and material. Feedback arrives before any tooling cost is committed.
XC cuts single layers and laminates, such as foam bonded to PSA and a liner, or Kapton bonded to copper foil and acrylic adhesive. A multi-layer stack is cut in one pass, so layers never drift out of alignment. EMI shielding gaskets, thermal pads and medical adhesive assemblies are typical.
Custom Die Cutting Tolerances
The table lists the general limits. The tolerance you get depends on the die type, covered in the next section.
Item | Specification |
|---|---|
General tolerances | ISO 2768-m |
Precision tolerances | As tight as ±0.2 mm, per drawing specs and GD&T annotations |
Minimum wall thickness | 0.5 mm |
Minimum part size | 10 × 10 × 1 mm |
Maximum part size | 1500 × 1500 × 10 mm |
Material thickness | 0.2 to 5 mm |
Prototyping | 1 to 100 pieces |
Low volume | 101 to 5,000 pieces |
High volume | Above 5,000 pieces |
Lead time | 3 to 5 business days for most projects. Simple parts can ship in 1 to 2 days |
Which Die Type Fits Your Job?
The die type sets tolerance, tooling cost and the order size that pays off. Use this chart before you request a quote.
Die type | Tolerance | Tooling cost | Tooling time | Order size |
|---|---|---|---|---|
Flatbed steel rule | ±0.25 mm, ±0.13 mm on stiff stock | $50 to $500 | 1 to 3 days | From 100 parts |
Rotary | ±0.05 to ±0.13 mm | $500 to $5,000 | 5 to 10 days | Above 10,000 parts |
Matched metal | ±0.025 to ±0.127 mm | $1,000 to $10,000 | 7 to 14 days | From 1,000 parts |
Kiss cut (adhesive parts) | Set by the die used | Set by the die used | Set by the die used | From 500 parts |
For thick foam or short runs where a die is not worth it, waterjet cutting needs no tooling at all.
Metal Foils and Shim We Die Cut
Metal is the smaller part of die cutting at XC. The live list names only aluminum foil, copper foil and thin steel shim. Our materials page covers the full range across all processes.
Aluminum foil cuts from 0.025 to 0.5 mm. It forms shielding and thermal layers in EMI gaskets and pads. Color is silver.
Thin steel shim stock cuts from 0.05 to 1.0 mm. Send the grade and thickness so we can match the die type.
XC has not named stainless in its die cutting list. Send the grade and thickness for a check.
XC has not published die cutting data for titanium. Send the grade and thickness for a check.
XC has not published die cutting data for brass. Send the alloy and thickness for a check.
Soft Materials We Die Cut
These are the core die cutting materials, with the thickness XC has published for each.
- Foam: polyurethane, open and closed cell, 2 to 50 mm.
- Rubber sheet: neoprene, EPDM, NBR and silicone, 0.5 to 25 mm.
- Gasket sheet: cork-rubber composite, 1 to 12 mm.
- Films: Kapton polyimide, 0.025 to 0.25 mm, and Mylar PET, 0.025 to 0.5 mm.
- Paper and fabric: Nomex aramid paper, 0.05 to 0.5 mm, and non-woven fabrics.
- Adhesives: pressure-sensitive adhesive tape rolls.
- Foil and shim: aluminum and copper foil, 0.025 to 0.5 mm, and thin steel shim, 0.05 to 1.0 mm.
Finishes and Add-Ons for Die-Cut Parts
Custom die cutting at XC Machining produces precise cuts with clean edges, but additional surface finishes may be required to enhance the part’s appearance, functionality, and durability.
Our Custom Die Cutting Prototype Manufacturing Capabilities
Provides injection molding for prototypes and custom parts, emphasizing expert support, competitive pricing, and faster production cycles.
Get reliable vacuum casting services for high-quality prototypes and production parts at competitive prices. XC Machining offers highly detailed casting parts with consistent quality.
Uses cutting, bending, and forming techniques to produce precision metal components suited for industrial, commercial, and manufacturing applications.
Specialist Industries
Bring Your Designs to Life with XC Machining
Experience precision engineering with XC Machining. From detailed prototypes to high-volume production, we’re here to turn your concepts into reality. Contact us today to discuss your project needs!
- 50+ CNC machines in-house
- 60+ materials in stock
- 120+ countries shipped
- 15+ DFM engineers on staff
- All uploads are secure and confidential
Die Cutting FAQs
What is the difference between die cutting and die casting?
Die cutting presses a steel blade through flat material such as foam, rubber, gasket sheet and adhesive film, with no heat. Die casting injects molten aluminum, zinc or magnesium into a steel mold to form 3D metal parts. They are separate processes. XC die cuts gaskets, seals and flat non-metal parts, and offers die casting as its own service.
What tolerance does XC hold for die-cut parts?
Tolerance depends on the die type. Flatbed steel rule holds ±0.25 mm, or ±0.13 mm on stiff stock such as hard rubber and plastic sheet. Rotary dies hold ±0.05 to ±0.13 mm on thin films and label stock. Matched metal dies hold ±0.025 to ±0.127 mm for precision gaskets and EMI shields. Compressibility, thickness and Shore hardness all affect the result.
What is kiss cutting and when should I use it?
Kiss cutting sets the die to cut through the top layer and stop at the release liner. The top layer can be adhesive foam, label stock or double-sided tape. The liner stays whole and protects the adhesive until use. Use it for peel-and-stick parts such as adhesive gaskets, foam mounting pads, wound care films and assembly tapes.
What materials can XC die cut?
XC die cuts polyurethane foam from 2 to 50 mm and neoprene, EPDM, NBR and silicone rubber from 0.5 to 25 mm. Cork-rubber gasket sheet runs 1 to 12 mm. Films include Kapton from 0.025 to 0.25 mm and Mylar from 0.025 to 0.5 mm. XC also cuts Nomex paper, PSA tape, aluminum and copper foil, non-woven fabric and steel shim to 1.0 mm.
What is the tooling cost and lead time for a custom die?
A steel rule die costs $50 to $500 and ships in 1 to 3 business days, which suits prototypes and medium runs. A rotary die costs $500 to $5,000 and takes 5 to 10 days, so it fits runs above 10,000. A matched metal die costs $1,000 to $10,000 and takes 7 to 14 days. Re-orders reuse the tooling at no extra tooling cost.
What is the lead time for die-cut parts?
First parts ship in 3 to 7 business days, covering DFM review, tooling, cutting and inspection. Re-orders from existing tooling take 2 to 5 days. Rush delivery of 2 to 3 days covers simple shapes on steel rule dies in stocked materials. XC returns the DFM review and quote within 12 hours of your file upload.
What is the minimum order quantity for die cutting?
Flatbed steel rule die cutting starts at 100 parts, and kiss cut adhesive parts start at 500. Matched metal dies start at 1,000 parts because the tooling costs more. Rotary die cutting makes sense above 10,000 parts. There is no maximum, and XC scales to 500,000 or more parts per run.
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