Custom Die Cutting Services
XC Machining custom die cutting converts foam, rubber, gasket materials, adhesive-backed films, and thin metal foils into precise custom shapes using flatbed steel rule dies (tolerance ±0.25 mm, material thickness up to 25 mm) and rotary dies (tolerance ±0.05–0.13 mm, high-speed continuous feed). Kiss cutting, through cutting, perforation, and scoring available. Steel rule die tooling in 1–3 business days. First parts in 3–7 business days.
- All uploads are secure and confidential
What Is Custom Die Cutting at XC Machining?
Custom die cutting at XC Machining uses a shaped steel blade (die) pressed against flat material to cut precise shapes — gaskets, seals, foam pads, adhesive labels, insulation sheets, and EMI shields — with tolerances from ±0.05 mm (rotary) to ±0.25 mm (flatbed steel rule), at volumes from 100 to 500,000+ parts.
Custom Die Cutting Solutions from Industry Experts
XC Machining is a leader in custom die cutting solutions, providing tailored services for industries like packaging, electronics, automotive, and manufacturing. Our custom die cutting experts bring years of experience to every project, ensuring that your parts meet strict quality standards.
As a reliable custom die cutting manufacturing company, we handle everything from material selection to final inspection, delivering parts that perform exactly as intended while maintaining competitive pricing for our USA customers.
Why Choose XC Machining for Custom Die Cutting Services?
XC Machining offers flatbed steel rule die cutting (tooling in 1–3 days, parts in 3–7 days), rotary die cutting (±0.05 mm, high-volume continuous feed), kiss cutting (adhesive-backed parts, liner intact), and matched metal die cutting (±0.025 mm precision). DFM review within 12 hours. ISO 9001:2015 certified.
XC Machining produces flatbed steel rule dies in 1–3 business days — laser-cut plywood board with custom-bent steel rule blade, calibrated to your part profile at ±0.25 mm tolerance. Low tooling cost ($50–$500) makes steel rule die cutting cost-effective for prototype quantities (100 parts) through medium production runs (50,000 parts), with no minimum order requirement.
XC Machining kiss-cut parts are calibrated to cut through the adhesive top layer and stop precisely at the release liner — 100% liner integrity verified by inline inspection. Peel force consistent within ±10% across the production run. Used for PSA gaskets, foam tape pads, and peel-and-apply insulation parts requiring adhesive protection through shipping and assembly.
Upload DXF or PDF file. XC Machining engineers review minimum feature size, minimum bridge width, corner radii, material compatibility, adhesive system, and die type recommendation — and return DFM feedback within 12 hours before any tooling cost is committed. Die type selection (flatbed, rotary, kiss cut, or matched metal) is based on your volume, tolerance, and material type.
XC Machining die cuts single-layer and multi-layer laminated constructions — foam bonded to PSA adhesive to release liner, or Kapton bonded to conductive copper foil to acrylic adhesive. Multi-layer stacks are die cut in one pass, eliminating alignment errors from cutting layers separately. Used for EMI shielding gaskets, thermal interface pads, and medical device adhesive assemblies.
Tolerances for Custom Die Cutting
| Description | Specification |
| General Tolerances | ISO 2768-m |
| Precision Tolerances | Tolerances as tight as ±0.2 mm, per drawing specs and GD&T annotations |
| Minimum Wall Thickness | 0.5mm |
| Minimum Part Size | 10mm x 10mm x 1mm |
| Maximum Part Size | 1500mm x 1500mm x 10mm |
| Material Thickness | 0.2mm to 5mm |
| Production Volume | Prototyping: 1-100 pcs |
| Low Volume: 101-5,000 pcs | |
| High Volume: Above 5,000 pcs | |
| Lead Time | 3-5 business days for most projects. Simple parts can be delivered as fast as 1-2 days |
Materials for Custom Die Cutting Parts
Leading companies and engineers rely on XC Machining for rapid iterations and durable, high-quality parts. Whether it’s for prototyping or full-scale production, our wide range of materials ensures we meet the unique requirements of any CNC Machining Services project with precision and speed.
Alloy steel 1215 Alloy steel 4140 Alloy steel 4340
Tool steel A2 Tool steel H13 Tool steel D2 Tool steel O1 Tool steel S7
Carbon steel C45
Mild steel 1018 Mild steel 1045 Mild steel A36 Mild Steel S235JR
Stainless Steel 17-4 PH Stainless steel 301 Stainless steel 304/304L Stainless steel 416 Stainless steel 440C
Surface Finishes for Custom Die Cutting
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. XinCheng 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
- Expertise Shared Widely
- Market Reach Expanded
- Advanced Technology Integrated
- Collaborative Innovation Opportunities
- All uploads are secure and confidential
Frequently Asked Questions
What Is the Difference Between Die Cutting and Die Casting?
Die cutting and die casting are completely different manufacturing processes. Die cutting uses a steel blade (die) to cut flat materials — foam, rubber, gaskets, adhesive films — into custom shapes without heat. Die casting injects molten metal (aluminum, zinc, magnesium) into a steel mold at high pressure to form 3D metal parts. XC Machining offers die cutting for gaskets, seals, and flat non-metallic parts. Die casting is a separate metal forming process.
What Tolerance Does XC Machining Hold for Die-Cut Parts?
Tolerance depends on die type: flatbed steel rule die — ±0.25 mm standard, ±0.13 mm on stiff materials like hard rubber and plastic sheet; rotary die — ±0.05–0.13 mm on thin films and adhesive label stock; matched metal die — ±0.025–0.127 mm for precision medical gaskets and EMI shields. Material compressibility, thickness, and Shore hardness all affect achievable tolerance. XC Machining recommends the optimal die type for your tolerance requirement during DFM review.
What Is Kiss Cutting and When Should I Use It?
Kiss cutting calibrates the die to cut through the top material layer — adhesive foam, PSA label stock, or double-sided tape — while stopping precisely at the release liner below. The liner remains intact and continuous, protecting the adhesive surface until point of use. Kiss cutting is used for all peel-and-stick parts: adhesive gaskets, foam mounting pads, wound care adhesive films, and assembly tapes. Liner integrity is verified 100% inline during production.
What Materials Can XC Machining Die Cut for Industrial Parts?
XC Machining die cuts: polyurethane foam (PU, open and closed cell, 2–50 mm), neoprene/EPDM/NBR/silicone rubber sheets (0.5–25 mm), cork-rubber composite gasket sheet (1–12 mm), Kapton polyimide film (0.025–0.25 mm), Mylar PET film (0.025–0.5 mm), Nomex aramid paper (0.05–0.5 mm), pressure-sensitive adhesive (PSA) tape rolls, aluminum and copper foil (0.025–0.5 mm), non-woven fabrics, and thin steel shim stock (0.05–1.0 mm).
What Is the Tooling Cost and Lead Time for a Custom Die?
Steel rule die (flatbed): $50–$500, produced in 1–3 business days — most cost-effective option for prototype and medium-volume runs. Rotary die: $500–$5,000, 5–10 business days — required for high-volume continuous-feed production above 10,000 units. Matched metal die (punch + die set): $1,000–$10,000, 7–14 business days — for precision tolerances of ±0.025–0.127 mm. Tooling is reusable for re-orders at no additional tooling cost.
What Is the Lead Time for Die-Cut Parts at XC Machining?
Total lead time: 3–7 business days for first parts (includes 1-day DFM review, 1–3 days tooling fabrication, 1–2 days production cutting, 1 day inspection and packaging). Re-orders from existing tooling: 2–5 business days (no tooling fabrication required). Rush delivery: 2–3 business days for simple shapes on steel rule dies from commonly stocked materials. DFM review and quote returned within 12 hours of file upload.
What Is the Minimum Order Quantity for XC Machining Die Cutting?
Minimum order quantity (MOQ): 100 parts for flatbed steel rule die cutting (tooling cost amortizes across small runs). 500 parts for kiss cut on adhesive materials. 1,000 parts for matched metal die (higher tooling investment requires larger run for cost-effectiveness). 10,000 parts recommended for rotary die cutting to justify rotary tooling cost. No maximum — XC Machining scales to 500,000+ parts per production run.
