There are a few choices when considering rubber for your gasket but Neoprene material is multi-purpose. It is an extremely versatile material that can be found in virtually every industry across the board.
Neoprene is usually supplied in sheet or roll form and can come in plain backing or with a adhesive (PSA) on 1 side, black color and to ASTM and Mil Spec.
Neoprene is a lightweight material made from synthetic rubber designed to be flexible, durable, resilient and very resistant to compression and liquids such as water, oil and other solvents. It can be used outdoors and has a 900 psi tensile strength operating at -30 degrees C to 200 degrees F.
We have worked with our Neoprene material suppliers and can now provide a quick delivery of 6 business days for quantities up to 500.
We can supply Neoprene Rubber in various thicknesses: 1/64”, 1/32”, 1/16”, 3/32”, 1/8”. 3/16”, ¼”, 3/8”, ½” and in various hardness: soft (10-35 duro), medium soft (40-45 duro), medium (50-55 duro), medium hard (60-65 duro), hard (70-85 duro).
At Alpha Die Cutting we supply customers with Neoprene Gaskets in a number of industries including electronics, industrial, automotive, medical, lighting, aerospace etc.
If you need a Gasket made from Neoprene please call Martin at (858) 279 3343 or e mail at email@example.com
EPDM rubber (Ethylene Propylene Diene Monomer) is a synthetic rubber that is UV-resistant rubber, something that could be used outdoors for extended periods of time without degrading. It has both elasticity and UV and ozone resistances and with high strength. EPDM’s resistance to weathering is the material’s defining feature.
It is used to create gaskets, seals, protective pads, and other various products.
We have worked with our material suppliers and are now offering a 6 business day delivery.
Purchase the EPDM material (sheet or roll), manufacture of the die and die cut the custom gasket.
We also offer a PSA on 1 side of the material with an additional 2 weeks onto the delivery.
Available EPDM has the following spec:
Temperature range -55 degrees to +300 degrees F.
Black in color, plain without adhesive backing.
Available in thicknesses 1/32”, 1/16”, 3/32”, 1/8”, 3/16”, ¼”.
Hardness duro, 40-45 medium soft, 50-55 medium, 60-65 medium hard, 70-85 hard.
Tensile strength 40A = 1200 psi, 50A = 1500 psi, 60A = 1800 psi.
To ASTM and Mil spec.
Recently a customer asked for help with a problem they were having with finding Gaskets they needed for older model carburetor re-builds.
The customer re-builds carburetors for the older type Porsche motor cars. They were finding that the old car Gaskets were no longer available from the OEM or were extremely expensive. In some cases they were being forced to buy a kit of parts when they just needed one type of Gasket.
Their first Gasket requirement was for the Porsche 356. They had a sample Gasket which we used as a model to reverse engineer the new Gasket. The main challenge was that no engineering drawing existed so specific details that we normally need to make a Gasket were not available. To overcome this, we electronically scanned the existing Gasket to produce a new drawing. We were then able to produce a custom die which we used to manufacture the new Gasket.
We found a suitable equivalent material on the McMaster Car web site. We decided on a lightweight vegetable fiber material, 1/64” thickness. This material was resistant to water, oil and inert gasses with a max pressure of 250 psi, -20 to +250 degrees F temperature range, per MIL-G-12803 spec and RoHS compliant.
The customer received the new Gasket within 2 weeks of initially asking us if we could help. See photo of the existing Gasket (red) and the new Gasket (brown).
Cost issue resolved by MOQ
The cost of making qty 1 Gasket is prohibitive but it is not so far out of bounds with a low MOQ quantity. The price all depends on the size and complexity of the Gasket but as a rough guide the die would be $125 which includes scanning and making a new drawing, with the price of making each Gasket at $0.50 each at a MOQ of qty 50. The only other cost would be the raw material.
Other EOL applications
There are lots of End of Life products where the OEM no longer provides supply chain support. If you have a carburetor re-build or any other project that needs a Gasket you can no longer source, please contact us: firstname.lastname@example.org
Other possible applications include all older car models, motor cycles, aerospace, marine vehicles etc.
Creative die cutting solution for cutting LEXAN material.
Over the last few years we have worked very closely with an OEM who manufactures a metallic product for the entertainment industry. They needed a ring made from a type of plastic that was hard wearing but most importantly had a critical and very small width dimension, 0.100”.
The small size of the part and the thickness of the material (0.010”) plus the exacting width dimension made this a very challenging project. But we enjoy a challenge and we were determined to find a solution.
We recommended Lexan Polycarbonate material as it is strong, impact resistant and durable which is ideal for the repeated usage and it can also be die cut quite easily.
Good so far, but the 0.100” width dimension is difficult to achieve. We tried the conventional ways of die cutting circles but our sample parts did not produce the 0.100” critical width dimension.
We finally had the idea of using 2 different rule profiles. So we made a new die which both cut right through the Lexan and also cut in 2 different positions at the same time and producing the required width dimension. Success.
This very creative die cutting was the perfect solution to a challenging problem.
Our engineering expertise with over 20 years die cutting experience plus our perseverance was the secret combination that manufactured a ring which met the critical width dimension.
We continue to push the limits of steel rule die cutting enabling us to deliver an excellent quality product with ever challenging requirements to our customers.
If you have a challenging seal or gasket manufacturing issue let us help you, call or email.
3 years ago our customer initially manufactured 1 product size but it’s now available in 3 different sizes (1.5”, 2.25” and 2.75” diameters). We have been able to apply our creative solution to all 3 models and now produce 3 different size rings, see photo.
In our experience we can save our customers between 25-50% using this clever technique
In most of cases the cost of the raw material is the most expensive element of die cutting manufacture so we always try our best to maximize the part yield from the raw material. This is especially important with part drawings which call out 1 side with PSA (Pressure Sensitive Adhesive) or if the part itself is made from an adhesive tape. When purchasing any raw material which has an adhesive side it always has a high MOQ. Because the adhesive has a short shelf life the raw material must be produced by the OEM or the distributor as a order on demand – raw materials with adhesive are not held in inventory.
One of the main ways that we can keep our customers costs to a minimum is a strategy of making the dies with more than one part number on them – this is called “nesting”. There are some requirements: that the customer requires multiple parts from the same raw material and that the number required of each part number is the same quantity. In our experience using this strategy reduces the total overall costs by between 25-50%.
One of our customers had a requirement for 3 small parts to be die cut manufactured using a 3M VHB (Very High Bond) adhesive tape. 3M VHB tape is very expensive and has an exteremly high MOQ. Using our maximum yield strategy we were able to make a die with the 3 parts nested together which resulted in a price to the customer at 60% it would have cost using qty 3 dies of each of the 3 parts individually, see photo.
If you have any questions regarding costs and how to maximize the use of the raw material please contact us at (858) 279-3343.
About the Author
With over 25 years of experience in the manufacturing industry, Martin Chell brings a wealth of knowledge to his client projects. He has worked with large companies including Qualcomm and completed projects in a variety of aerospace, biotech and other applications.
“The die cut samples look great.” ~ Aquapail
“Thanks so much for the great service.” ~ Robert, Hat Fitness
“The gaskets worked out just fine. Thanks for your help.” ~ Chong, Redpoint Engineering