Providing Custom Turnkey Manufacturing Solutions to Convert Your Ideas to Life

Providing Custom Turnkey Manufacturing Solutions to Convert Your Ideas to Life

Precision Rotary Die Cutting Services

The Basics of Precision Rotary Die Cutting Services

Rotary die-cutting is a form of precision die-cutting that uses custom-made cylindrical dies and a rotary press to convert a wide array of materials from roll stock to a finished device. Pepin Manufacturing, Inc. uses precision die-cutting technologies, utilizing machines that can feed one or multiple materials into a die-cutting station, which features a rotary die and a hardened anvil cylinder. The rotary die cylinder, which contains the part image, presses against the hardened anvil cylinder’s surface and cuts out a specific shape using the raw material in between.

Advantages of die-cutting include its potential to create nearly any shape with precision rotary die-cutting technologies and equipment, including specific die cuts, slits, or perforations. The die-cutting process is designed to produce high-tolerance parts at extremely high volumes. Pepin Manufacturing, Inc. can either produce a finished component or provide subassemblies to our customers in rolled form.

Pepin Manufacturing’s Versatile Rotary Die Cutting Services

We use state-of-the-art servo-driven rotary presses capable of producing custom disposables to customer specifications for our rotary die cutting services. We can achieve tolerances as low as +/- .004” on die-cut parts using our CCD vision technology. Over the past three decades, we’ve helped solve many challenging projects which require precision rotary die cutting services to produce one-of-a-kind products for our customers.

We can provide small-run functional prototyping utilizing our die-cut technologies and clicker press. With our rapid prototyping service, tooling lead time is reduced from weeks to days, allowing us to manufacture and ship functional prototypes within a short period of time.. If you require medium to large-production volume, our high-output precision rotary die-cutting presses would be capable of meeting your production demands. Our customers include start-ups, Fortune 100 companies, and everything in between.

Have any questions about our precision rotary die cutting services or manufacturing solutions? Please contact our in-house manufacturing experts to discuss the advantages of die-cutting.

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The Advantages of Servo-Driven Precision Rotary Die Cutting 

To achieve precision in rotary die-cutting, it comes down to utilizing advanced die-cut technologies which include having a control system capable of accurate tension control and in-line registration. Servo-driven rotary presses allow for more precise cutting, resulting in the ability to produce more complex parts with tighter tolerances over traditional die-cutting machines. This type of equipment uses an advanced PLC mixed with servo motors to control the tension and speed of each station of the press, allowing to advance or slow down each station to allow for precision rotary die-cutting. 

With individual servo motors at each rotary die-cutting station, the modules can be adjusted independently of one another, allowing for the die-cut to be changed quickly. This allows for precision cuts, even when the registration marks are inconsistent. Pepin’s closed-loop CCD vision system can provide real-time servo adjustments to further increase die-cutting tolerance to as low as +/- .004”.

Our Precision Rotary Die-Cutting Capabilities Include:

  • Flexographic printing
  • In-Line precision rotary die-cutting
  • Laser die-cutting
  • Kiss cutting
  • Sheeting
  • Complex web handling
  • Vacuum pick-and-place
  • Bull-nose transferring
  • Perforating
  • Multi-layer laminating
  • Scoring
  • Island placement

Our team ensures that our products meet or exceed all applicable industry standards and accreditations from ASTM, ANSI, CSA, CE, RoHS, and the FDA. We use state-of-the-art servo-driven rotary presses capable of producing custom disposables to customer specifications for our rotary die cutting services. We look forward to assisting with your die cutting service needs. Contact us at 1-800-291-6505 for more information or to get started on a quote today!

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Our Rotary Die Cutting Services Are Compatible With These Materials:

  • Fabrics & nonwovens
  • Highly conductive films
  • Dielectric tapes
  • Closed-cell and open-cell Foams
  • Very High Bond Tapes (VHB)
  • Pressure-sensitive tapes & adhesives
  • Polyimide
  • Polyester
  • Hydrogels
  • Polyurethane films
  • Polyethylene films
  • Textiles
  • Vinyl
  • Various medical & industrial grade materials

Our ISO-13485 Certified Medical Facilities Can Perform Additional Services:

  • Slitting
  • Sewing
  • LEAN Manufacturing/Cell Systems
  • Custom assembly & box build
  • Flexographic printing & screen printing
  • Ultrasonic welding
  • Shrink wrapping
  • Custom box build
  • Design for Manufacture (DFM) 
  • Computer Aided Design (CAD)
  • UV Curable adhesive dispensing/bonding
  • Custom jigs for short-run prototyping
  • Soldering 
  • In-line thermal & cold  forming
  • Packaging, labeling, & kitting services

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.

What Our Clients Have to Say

“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

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Precision Rotary Die Cutting Highlights

General Capabilities
Precision rotary die cutting
In-line multiple die cut registration
Kiss cutting
Multi-Layer Lamination
Island Placement
Die Cutting Method
Adhesive Backed Materials
Conductive materials
EMI/ RFI shielding materials
Films (All types)
Foams (All types) PE, Poron, ect.
Hydrocolloids/ ostomy materials
Medical grade materials
Pressure Sensitive Materials
Pressure sensitive tapes and adhesives
VHB material
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
Material Sourcing
Island Placement
Flat Bed Screen Printing
Ultrasonic Welding
Coldseal Packaging
Membrane Switch Manufacturing
Contract Assembly
Steel Rule Die Tooling
Machine Shop
Automated Packaging
Private Labeling
Custom Kitting
Production Volume
Small Run Prototyping
Large Scale Production Volume Run