We were recently asked about die cutting a SAE F-13 felt at ¾” thickness. The customer wanted a part made for their Battery application. We had no prior experience with this material before, but we were confident we could cut the material to produce the OD of the part but not so sure about the small dimensional slots. Die cutting the part would be a challenge because of the combination of the material thickness, the material density and the narrow dimensions of the slots.
Our initial response to the customer was to be completely transparent and say that we were not sure we could make the part but would be willing to conduct some R&D to determine if this project was possible. The R&D effort involved purchasing the F-13 felt material, to make a custom die and a few different die cutting attempts. We have now successfully produced the required part.
Industrial S.A.E (Society of Automotive Engineers) Wool Felt.
This is a felt used where resistance to abrasion, durability and wear are not so important. Applications such as spacing strips, sound deafening, fuel oil filters, anti-rattle, grease and oil retention.
The felt varies in thicknesses, colors, densities and composites specified by the SAE designation i.e. F-X.
If you want to know more about this capability or send a RFQ please e mail email@example.com
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 firstname.lastname@example.org
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: email@example.com
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.
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