Precision Rotary Die Cutting Services
Expert Precision Rotary Die Cutting Services for Custom Manufacturing Needs
Pepin Manufacturing, Inc. (PMI) provides expert precision rotary die cutting services designed to meet the exact requirements of industries ranging from medical and industrial to aerospace and retail. Located in Lake City, Minnesota, and backed by decades of experience, our ISO-13485-certified facility is equipped to handle complex projects that demand the highest level of precision, consistency, and customization.
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What Are Precision Rotary Die Cutting Services?
Precision rotary die cutting services involve the use of custom-engineered rotary dies to convert flexible materials into highly accurate, repeatable shapes and parts. This process is ideal for high-speed, high-volume production runs and is essential for applications that require tight tolerances and consistent product quality. At PMI, we specialize in working with a wide variety of materials, including tapes, adhesives, foams, films, nonwovens, and hydrogels.
Our precision rotary die cutting services are tailored to the unique requirements of each project, ensuring optimal results whether we’re producing medical components, industrial gaskets, or retail packaging solutions.
Benefits of Choosing PMI’s Precision Rotary Die Cutting Services
When you partner with PMI for precision rotary die cutting services, you gain access to exceptional accuracy achieved through our state-of-the-art equipment, which ensures clean, uniform cuts for complex geometries and tight specifications.
We also offer material versatility, expertly converting everything from thin films to pressure-sensitive adhesives. Each rotary die is custom-engineered to meet the exact design and function specifications of your application, ensuring precision and performance at every stage. Our streamlined processes also help reduce waste and improve material yield, leading to greater cost efficiency and more value per unit.
Industries We Serve With Our Precision Rotary Die Cutting Services
Our precision rotary die cutting services are trusted across a wide range of industries. In the medical field, we produce single-use diagnostic devices, electrodes, wound care products, and more. Aerospace and defense clients rely on us for high-performance insulation materials and custom components capable of withstanding demanding conditions. Industrial manufacturers depend on us for gaskets, seals, and vibration-damping parts tailored to unique applications.
Our services in the retail and consumer goods sector include the production of custom-shaped labels, packaging inserts, and adhesive-backed products. We also support cosmetic and personal care brands by producing precision-cut pads, patches, and other consumer-ready solutions.
Integrated Capabilities and Value-Added Services
At PMI, our precision rotary die cutting services are integrated with a comprehensive range of complementary capabilities. Our product development services enable close collaboration with clients to refine and optimize designs before scaling to production. Our team helps with material sourcing and sampling, leveraging our supplier relationships to select materials that meet performance goals and budget constraints.
Printing services allow us to apply branding, instructions, or product identifiers directly to die-cut components, enhancing product functionality and presentation. We also provide packaging and assembly services to deliver finished, ready-to-use products, simplifying logistics and speeding time to market.
Quality and Compliance
As an ISO-13485-certified facility, PMI ensures that all precision rotary die cutting services meet the most rigorous quality and regulatory standards. Our quality assurance team oversees each stage of the manufacturing process, from raw material inspection to final product testing. Full traceability and strict adherence to industry-specific regulations provide clients with confidence and peace of mind.
Customization at Every Level
We understand that no two projects are alike. Our precision rotary die cutting services are fully customizable, supporting unique shapes and cut patterns, multi-layer laminations, and inline processes such as perforation, scoring, and registration. Whether your project requires tight tolerances for critical dimensions or specialized fabrication techniques, PMI develops a tailored solution that delivers consistent performance, durability, and value.
Why Choose PMI for Precision Rotary Die Cutting Services?
What sets PMI apart is our unwavering commitment to partnership. We don’t just deliver parts—we deliver peace of mind. From initial specification to final product delivery, our team offers hands-on support, in-depth technical expertise, and responsive communication to ensure your success. Choosing PMI for your precision rotary die cutting services means selecting a partner who is as invested in your project’s outcome as you are. With flexible manufacturing capabilities and extensive industry experience, we provide solutions that align with your timeline, your performance standards, and your bottom line.
We can assist with design for manufacturability, allowing us to reduce overall manufacturing costs. Our experienced product development team will listen to your project requirements and source-specific materials from our extensive supplier network to optimize your product’s performance. Contact our experts, who are ready to discuss the advantages of precision rotary die-cutting services and how they can benefit you.
Hear It from Our Clients
“Pepin was recommended to us by another manufacturing plant due to their expertise and experience with converting. We brought a complicated problem that many other converters have not been able to figure out and Pepin and their team have invested into this project even without promising results right away and they were able to perform the task. After a few runs, Pepin’s team spent ample hours collaborating and brainstorming some ideas and came up with a solution. SOSCO is so thankful for the relationship we have built with Pepin and continue to build. I also think the F-35 Fighter Jet team appreciates them as well!”
– Maci Pieper, Director of Operations at Sosco
Precision Rotary Die Cutting Highlights
General Capabilities
- Precision rotary die cutting
- In-line multiple die cut registration
- Kiss cutting
- Sheeting
- Perforating
- Multi-Layer Lamination
- Island Placement
Die Cutting Method
- Rotary
Materials
- Adhesive Backed Materials
- Cloth
- Conductive materials
- EMI/ RFI shielding materials
- Fabrics
- Felt
- Films (All types)
- Foams (All types) PE, Poron, ect.
- Foils
- Hydrocolloids/ ostomy materials
- Hydrogels
- Kapton
- Medical grade materials
- Neoprene
- Non-Wovens
- Papers
- Polyesters
- Polyethylenes
- Polyimide
- Polyurethanes
- Pressure Sensitive Materials
- Pressure-sensitive tapes and adhesives
- PVC
- PVDF
- Silicone
- Textiles
- Urethane
- VHB material
- Vinyl
Additional Services Provided
- Wide Web Slitting
- Narrow Web Slitting
- Multi-Layer Laminating
- Flexographic Printing (up to 4 color)
- High-Speed Thermal Inkjet Printing
- Thermal Transfer Printing
- Custom Packaging & Labeling
- Sewing
- Material Sourcing
- Island Placement
- Flat Bed Screen Printing
- Engineering
- CAD
- Ultrasonic Welding
- Soldering
- Rewinding
- Coldforming
- Coldseal Packaging
- Membrane Switch Manufacturing
- Perforating
- Sheeting
- Embossing
- Contract Assembly
- Steel Rule Die Tooling
- Machine Shop
- Automated Packaging
- Private Labeling
- Custom Kitting
Production Volume
- Large Scale Production Volume Run
Precision Rotary Die Cutting Services—Frequently Asked Questions (FAQ)
What is precision rotary die cutting?
Precision rotary die cutting is a high-speed manufacturing process that uses custom-engineered rotary dies to convert flexible materials into precise, repeatable parts. The process allows for extremely tight tolerances, complex geometries, and consistent product quality. It is ideal for both high-volume and mid-scale production runs where accuracy and efficiency are essential.
What makes rotary die cutting different from other cutting methods?
Rotary die cutting uses a cylindrical die to cut or shape materials as they pass continuously through a press. Unlike flatbed die cutting, which uses a flat die and is better suited for thicker or low-volume applications, rotary die cutting is ideal for high-speed, high-volume production runs that require repeatable accuracy. This process ensures consistent quality across thousands or even millions of parts.
What materials can PMI process with precision rotary die cutting?
Pepin Manufacturing works with a wide range of flexible materials, including but not limited to:
- Pressure-sensitive adhesives and tapes
- Medical-grade hydrogels and hydrocolloids
- Films, foils, and polyesters
- Non-wovens and textiles
- Urethane, foams (PE, Poron, etc.), and neoprene
- Conductive materials and EMI/RFI shielding materials
- PVC, PVDF, Kapton, and silicone
- Specialty materials for aerospace, defense, and healthcare
Our expertise in material selection ensures that every project is matched with the right substrate for performance, durability, and cost-effectiveness.
What level of precision can PMI achieve with rotary die cutting?
Our state-of-the-art equipment allows us to maintain extremely tight tolerances, often within thousandths of an inch. This precision ensures that even complex shapes and detailed cut patterns are reproduced accurately across every production run. For industries like medical, aerospace, and electronics, where dimensional accuracy is critical, our rotary die cutting services deliver dependable consistency.
Is rotary die cutting suitable for adhesive-backed products?
Absolutely. Rotary die cutting is an excellent solution for processing adhesives, including pressure-sensitive materials, medical adhesives, and double-sided tapes. We also offer kiss cutting, where only the top adhesive layer is cut while the liner remains intact, allowing for easy peel-and-apply functionality.
Can PMI integrate printing with rotary die cutting?
Yes. We offer inline and secondary printing options that allow branding, instructions, or lot numbers to be printed directly on die-cut components. This value-added service eliminates extra steps in your supply chain and ensures your finished product is market-ready.
How does PMI ensure quality and compliance?
As an ISO-13485-certified facility, PMI operates under strict quality management and regulatory guidelines. Our quality assurance team monitors every stage, from raw material inspection to final testing. We maintain full traceability, giving clients peace of mind that every product meets industry-specific compliance requirements.
Does rotary die cutting reduce material waste compared to other methods?
Yes. One of the benefits of rotary die cutting is its ability to optimize material usage. Our process is designed to minimize scrap while maintaining tight tolerances, which improves yield and reduces costs. This is particularly valuable when working with expensive materials like medical-grade adhesives or specialty films.
Can PMI handle multi-layer laminations during die cutting?
Yes. Multi-layer laminations are a key part of our rotary die cutting capabilities. We can bond and cut multiple layers of materials in one continuous process, producing components such as layered electrodes, diagnostic devices, or insulation pads. This not only streamlines manufacturing but also ensures precise alignment across all layers.
What industries benefit most from precision rotary die cutting?
PMI’s services support a wide variety of industries, including:
- Medical: Single-use diagnostic devices, wound care products, electrodes, patches, and more.
- Aerospace and Defense: Custom insulation, vibration-damping components, and specialty materials built to withstand extreme conditions.
- Industrial: Gaskets, seals, and custom components for manufacturing and equipment applications.
- Retail and Consumer Goods: Labels, packaging inserts, and adhesive-backed products.
- Cosmetics and Personal Care: Precision-cut pads, patches, and other consumer-ready solutions.
What is kiss cutting, and does PMI offer it?
Kiss cutting is a rotary die cutting technique where only the top layer of a material (such as an adhesive liner) is cut, leaving the backing intact. This allows for easy peel-and-apply functionality. PMI regularly provides kiss-cut components for medical devices, labels, and industrial adhesives.
Can PMI print directly onto die-cut parts?
Yes. PMI offers flexographic printing (up to 4 colors), thermal inkjet printing, and thermal transfer printing directly on die-cut components. This capability allows for branding, instructions, lot codes, or other critical information to be applied inline, reducing extra steps in the production process.
Does PMI provide secondary services beyond die cutting?
Absolutely. In addition to precision rotary die cutting, PMI offers:
- Multi-layer laminating
- Wide and narrow web slitting
- Coldseal and cold-forming packaging
- Ultrasonic welding and soldering
- Custom kitting, contract assembly, and private labeling
- Engineering and CAD support for design optimization
These value-added services allow clients to consolidate multiple steps into a single, streamlined partnership.
Can PMI create highly complex, custom die-cut parts?
Yes. PMI excels in custom projects that require specialized cut patterns, intricate designs, or tight tolerances. We can accommodate multi-layer laminations, perforations, embossing, scoring, and island placement—all tailored to your specifications. Our engineering team works closely with you to ensure your parts are both functional and cost-effective.
What project volumes can PMI support?
PMI is equipped for medium and large-scale production volume runs. Whether you need thousands or millions of parts, our facility can scale to meet your needs efficiently.
Get Started With Precision Rotary Die Cutting Services Today
Ready to bring your next project to life with precision rotary die cutting services? Contact the experts at Pepin Manufacturing, Inc. to discuss your application, request a quote, or schedule a consultation with our engineering team.
Let us show you how our precision rotary die cutting services can enhance your product quality, streamline production, and reduce costs—all while delivering the reliability and expertise you expect from a trusted contract manufacturing partner. We look forward to learning about your unique manufacturing challenges and helping you create a solution that exceeds expectations.