Insul-Fab Custom Die Cutting Services

A Cut Above the Rest

Over the last 30 years, Insul-Fab has mastered the process of die cutting through the use of innovative practices, state of the art equipment, and trusted quality driven die makers. In order to produce quality parts with minimal waste when cutting a variety of materials it falls upon the quality of the die, the nesting of the of the parts, and the determination and expertise of the press operator to save our customer money.  Materials and products we commonly die cut include:

• Foam, Sponge Rubber, solid rubber, and silicone for gaskets and pads
• Thermal Insulation made from fiberglass and foam
• Acoustical Insulation made from polyester fibers, foam, and fiberglass
• EMI Shielding Laminates made from foils laminates and conductive EMI Gaskets
• Adhesives and adhesive backed materials, including VHB
• Dielectric Films and Papers for electrical insulation and baffles made from Formex, Nomex ,etc
• Thermal Interface materials, such as gap pads from FujiPoly

Insul-Fab incorporates a diverse collection of die cutting presses to satisfy every possible cutting requirement. Multi-Layer cutting, kiss-cutting, in-line lamination, hot foil stamping, trimming of molded parts, and rotary die cutting, are just a sample of the fabrication capabilities we can satisfy.

This array of presses allows Insul-Fab to utilize an unlimited assortment of tooling, from your basic Steel Rule Dies to Match Metal, Class “A”, Compound, Multi-Stage, Feed Through and Zero Clearance Die designs as well as Rotary. Insul-Fab has the equipment and the knowledge to cut and deliver high quality die cut parts for any application or capacity.

Markets Served

Insul-Fab fabricates for many different markets for locations all over the world.  We take great pride in our ability and history in servicing of our smallest customer to our largest in the same fashion.  Markets we serve include:

• Electronics
• Medical
• Communication and Storage
• Military
• Aerospace
• HVAC and Appliance
• Packaging
• Energy
• Heavy Truck and Automotive

Quality Die Cutting

Insul-Fab expects to deliver quality parts every time a shipment leaves one of our three locations.   Our plants in Dallas as well as Tyler, Texas, and Monterrey, Mexico utilize Quality Processes certified to ISO 9001:2008 and AS9100B.  We are ITAR compliant and offer RoHS certification on finished products when applicable. 

Initial Part Qualification is the key to duality die cutting.  While First Article Inspection (FAI's) offer the basic level of initial part qualification, we can also provide PPAP's, Process Management Plans (PMP's), SPC data collection, and sample retention for demanding military, medical, aerospace, and automotive customer expectations.

Design for Manufacture

While it is true that die cutting is relatively an easy process that utilizes a sharp blade and a form of pressure that drive this blade through materials, Insul-Fab will work with the customer throughout the design, specification, and material selection process to ensure that OEM parts are designed for efficient manufacture and best material yield.  In addition, we will provide prototypes in most cases in 3-5 days at minimal to no-charge to our customers. 

In the event that die cutting is not the best manufacturing method for a part, due to volume, tolerances, or other factors, we can easily offer one of our other services, such as Water Jet Cutting, Laser Cutting, or CNC Routing/Machining.