Die-Cutting Services

Die cutting is one of the most reliable ways to convert flat sheet materials into precise, repeatable custom parts. At Foamtec Specialty, our die cutting services turn foam, rubber, felt, film, and adhesive-backed substrates into components engineered to exact customer specifications from single prototypes to high-volume production runs.

As a specialty converter with ISO-certified manufacturing, we combine precision die cutting equipment with in-house tooling and material expertise to deliver consistent quality across every batch, regardless of part complexity.

punching in control room
Magnetic cylinder

What Is Die Cutting?

Die cutting, sometimes called punching, is a manufacturing process that uses a shaped blade — the die — to cut or stamp materials into a specific shape or create precise holes at designated points. It works much like a hole punch on paper, but at industrial scale, with the die’s shape, sharpness, and applied pressure adjusted to match the material and the finished part’s requirements.

Because the die is a fixed tool, every part cut from it is dimensionally identical to the last, which makes die cutting one of the most cost-effective processes available for custom die cutting at volume.

How Die Cutting Works

Our die cutting process follows a controlled sequence to ensure every part meets specification before it reaches production:

1

Material selection

We confirm the substrate (foam, rubber, felt, film, or laminate) and thickness best suited to the application.
2

Die design and tooling

A custom die is engineered to the part geometry, whether a simple shape or a complex, multi-feature profile.
3

Press setup

The die is mounted and pressure, speed, and depth are calibrated for the specific material.
4

Cutting

The press applies controlled force, cutting the material cleanly through (through-cutting) or partially through a backing/liner (kiss cutting).
5

Inspection and finishing

Parts are checked against dimensional tolerances, then kitted, sheeted, or packaged per the order.

This repeatable sequence is what makes die cutting ideal for large-scale industrial applications where consistency, accuracy, and traceability are non-negotiable.

Die Cutting Capabilities

Our precision die cutting services are built to handle a wide range of part sizes, tolerances, and production volumes without compromising repeatability.

CAPABILITY SPECIFICATION
Cutting methods Through-cutting, kiss-cutting, perforating, scoring
Material thickness range Thin films up to thick foam/rubber laminates
Tolerance Tight, repeatable tolerances suited to precision applications
Order volume Prototype and short-run to full production runs
Value-added services Kitting, sheeting, laminating, adhesive backing, packaging
Quality systems ISO-certified manufacturing with BSI and BV certifications

Materials We Die Cut

Foamtec’s die cutting services support a broad material range, giving customers a single-source partner from material selection through finished part:

Foam

open-cell and closed-cell foams for cushioning, sealing, and protective packaging

Rubber

Sponge and solid rubber for gaskets, seals, and vibration damping

Felt

for sound dampening, buffing, and low-friction applications

Film

thin, flexible substrates for insulation and barrier applications

Adhesives

Adhesive-backed and laminated materials

 Not sure which material fits your application? 

Explore our materials

or talk to our engineering team.

 Not sure which material fits your application? 

Industries and Applications

Our die cutting capabilities support component manufacturing across:

Aerospace

lightweight insulation, seating, and protective components

Green Energy

ealing and insulation components for renewable energy systems

Automotive

interior padding, gaskets, and sound-dampening parts

Medical

precision-cut parts for equipment padding and device components

Electronics

protective packaging, insulators, and vibration-dampening inserts
girl wearing headphones

Why Choose Foamtec Specialty for Die Cutting

  • ISO-certified manufacturing backed by BSI and BV certifications
  • Material expertise across foam, rubber, felt, film, and adhesives
  • Engineering support from initial design through production tooling
  • Global manufacturing capacity to support both prototype and high-volume orders
  • Complementary converting processes  slitting, lamination, and laser cutting available in-house for complete component solutions
Contact our team

Frequently Asked Questions

What is die cutting used for?

Die cutting is used to convert flat sheet materials such as foam, rubber, felt, and film into precise, repeatable shapes for applications like gaskets, seals, insulation, cushioning, and protective packaging.

What materials can be die cut?

Foamtec die cuts foam, rubber, felt, film, and adhesive-backed or laminated materials. If you’re unsure whether your material is suitable, our team can advise during the quoting process.

What's the difference between die cutting and laser cutting?

Die cutting uses a custom-shaped tool to cut parts and is most cost-effective at mid-to-high volumes. Laser cutting is a tool-less process better suited to prototyping, intricate details, or lower production volumes.

What is the minimum order quantity for die cutting?

Foamtec supports both prototype/low-volume runs and full production orders. Contact us with your part specifications for a tailored quote.

How long does die cutting tooling take?

Tooling lead times depend on part complexity and die type. Our team can provide a timeline once your design and material are confirmed.

Can die cutting handle multi-layer or laminated parts?

Yes. Foamtec can laminate materials in-house and die cut the resulting construction into a single finished part in one pass.