Quite simply, a converter converts. We take raw materials like foam, plastics, and adhesives and convert them into custom die-cut parts. For example, one of our customers might want a piece of foam that adheres to their molded plastic part. We take the sheet of foam, apply the adhesive and cut it into the shape that the customer needs.
What materials can you convert?
On any given day we are converting plastic, chipboard, adhesives, foams, paper, rubber, steel, and many other products. Challenge us with your project.
What is a Steel Rule Die?
A Steel Rule Die is simply a fancy cookie cutter. Unlike a cookie-cutter it is much tougher and much sharper and should last a really long time! All tooling life is dependent upon the machine, the material, and the operator.
Do I have to pay for tooling?
Yes and no! If you are looking for a custom shape then normally you have to purchase a tool. The good news is that we make tools in-house, so we’re not marking them up, like all the other converters that we supply tooling to. Once you purchase the tool, we keep it here and maintain it for every run.
If you are looking for perforated rolls of protective film, we normally don’t have to charge a tooling charge. Our equipment allows us to dial in any perf length that you require (almost).
Can I just purchase a tool?
Yes you can. We make and ship Steel Rule Die tooling every single day.
How do I pay?
Once we set up your account, our standard terms are 30 days. We also accept Visa/MC or PAYPAL.
What is PPAP?
A PPAP is an automotive acronym that stands for Production Parts Approval Process. It is a quality document that is done very often before the kick-off of a production part for the automotive industry. It ensures that the part can be made to print and that we have the capacity to produce the volumes quoted. We do them every day and can walk you through yours.
What is the lead-time?
Our normal, quoted, lead time is 2-4 weeks. That said, we try and meet the needs of all of our customers. If you need it quicker, give us a call, we may be able to help.
Can I get a sample?
Very often, yes. We stock many of the materials that we quote and are usually able to ship you a sample.
Is my job too small?
No. Never. While many of our competitors would say no to your job or charge a large minimum, we are glad to help.
Is my job too big?
No. We’ve run 2,000,000 parts a month for Dell computer as well as a pharmaceutical job that has an annual volume of 30,000,000 pieces. Our converting equipment allows us to run at very high speeds should your job demand it.
A method of converting raw materials with a die-normally a Steel Rule or Rotary tool. In both cases, a sharp tool cuts through a material to produce a finished part.
Adding shape to a flat material, using a male/female die, by applying heat, pressure and time. Cold embossing is also possible.
The process of cutting through one material, but not the other. Often we cut through a material to provide a “tab” for easy application. Think “vinyl decals” they are very often “kiss-cut.”
The process of mechanically bringing together two materials, usually with the assistant of nip rollers under pressure. Usually, one of the two materials is, or has, a pressure sensitive adhesive.
The paper or PE (polyethylene) that we use to “liner” an adhesive. Very often we “back-slit” it to aid in the end users application.
The process of putting a perforation in a material for easy application. Very similar to the perforation in a roll of paper towels. We can vary our perf from less than one inch to twenty feet.
Production Part Approval Process (from Wikipedia): is used in the automotive supply chain to establish confidence in component suppliers and their production processes, by demonstrating that:
“….all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.” Version 4 March 1st 2006.
Pressure Sensitive Adhesive – Most of the adhesives that we convert are pressure sensitive. That means that they need initial pressure when applying them to the surface. Normally they do not require additional water, solvents or heat to secure the bond.
The process of unwinding and rewinding a roll of material, very often we convert a master roll into smaller and/or shorter rolls.
Rotary die-cutting uses a die that is made in the shape of a cylinder. The die-cutting happens as the material is run through the press at very hi-speed and the tool rotates with it, cutting against an anvil.
Large rotary web presses can use rotary steel rule dies – mid and narrow web rotary presses (like we use) utilize solid steel machined cylinders to die-cut at hi-speed with great accuracy. Mid and narrow web rotary die-cutting works best when the material is thin, available in a roll, and the volume is high. Rotary tools are generally more expensive than Steel Rule tools.
The actual steel blade that is used to build steel rule tooling out of. Very precise and incredibly accurate.
(from Wikipedia) Also known as log slitting-a shearing operation that cuts a large roll of material into narrower rolls. The log slitting terminology refers back to the historic times of saw mills when they would cut logs into smaller sections for transportation.
Many industries, like automotive, have a defined set of conditions that they use to help classify and grade materials. Before we quote a job, we may very well ask, “Does it need to meet any specs?”
What is the adhesive part adhering to? In knowing what the die-cut part will be applied to helps us determine which adhesive or protective product we should use. Very often our Sales team will ask, “What is the ‘surface’ that you are adhering to?”
The backing, or base material, for a single sided adhesive. Typically a polyester.
Steel Rule Die
A tool used for cutting papers, plastics, foams, adhesives, rubber and many other materials. The die is made of very sharp, incredibly accurate, blades which are held together with a high-grade and high-density plywood; the plywood is usually composed out of hardwoods such as maple and are free from voids or other imperfections.
Dies are made either flat or rotary. We make flat steel rule dies for “the trade” or in-house use.
A method of die-cutting that uses heat to cut. Allows low-cost kiss-cuts of any shape to be made from vinyl film-decals or signage. Thermal dies are often photo etched magnesium.