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Steel rule die cutting is an effective way of mass producing die cut components with a minimal amount of expense. It is one of the main fabrication methods available at American Micro Industries. We can work with a range of different materials — including plastics, rubber, films and more — to meet your technical requirements and quickly turn around completed projects with a high level of accuracy.

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What Is Steel Rule Die Cutting?

Steel rule die cutting is a type of die cutting used to fabricate raw materials into a certain shape. It involves punch cutting a selected stock material into a particular form or pattern with a sharp steel rule against a flat surface. This technology is a material displacement method, meaning it doesn’t change the composition of the material itself. It only manipulates and separates the desired part from the waste.

How It Works

Steel rule die cutting uses a custom steel tool to punch material into a certain shape. Three components are involved: a cutting edge, a die board and a rubber ejector. The die board is a flat surface made from hard materials like wood, steel or composite, which has a thin groove the shape of the desired part cut into it, usually by a laser.

The cutting edge — a thin metal blade — is bent into shape either by hand or machine and placed onto the die board, where it is overlaid with a rubber ejector material.

Operating the die involves feeding a material in and stamping the tool into it. This causes the material to break along the cutting edge. Then, the rubber ejector pushes the cut part out of the steel die. An ejector can cover the entirety of the die or only a part of it.

Material Options

Materials that are too brittle or too soft are not good candidates for steel rule die cutting. The process requires the material to fracture and separate from just the right amount of force. Rigid materials will often fracture before the steel rule cutting blade gets through, resulting in inconsistent edges. Some soft materials often deform too much or fail to separate cleanly when cut.

Foam, cardboard, cork, rubber and plastic are generally good options that can be used to create products such as gaskets, electrical insulating components and foam inserts. These semi-rigid materials and similar items can be mass-produced with a high degree of consistency and repeatability. As a result, you’ll frequently find steel cut die components in products such as electronics, enclosures, plumbing and HVAC equipment, among others.

Example applications of steel rule die cutting include:

Electrical insulation: By cutting specialty insulation materials like E-FR board or fishpaper, we can create custom electrical protection for electronic devices, instruments and appliances.
Packaging: Many foam varieties can be cut out to protect delicate items. Our precision die cutting creates flexible or lightweight inserts for the level of safety you need.
Seals and gaskets: Automotive, medical, HVAC and other industrial gaskets are often made with high tolerances. Gasket materials used for steel rule die cutting include synthetic rubbers, thermoplastic elastomers and other options, depending on the specifications.

Key Benefits of Using Steel Rule Dies

The main advantages of steel rule die cutting include:

Accuracy: Precision die cutting achieves uniform results with minimal deformation or slivering of the material’s edges. The process creates clean cuts and won’t warp or bend materials.
Simplicity: The most basic steel die cutting process requires just three parts to set up. After assembly, these components can cut simple parts with a single stroke. Rotary die machining is better suited for kiss cutting and other operations involved in creating more complex parts.
Low tooling costs: Steel rule die cutting can produce a high volume of items at an economical rate, which is advantageous for short or medium production runs.
Versatility: Steel rule dies can transform materials of various thicknesses and types. The resulting component can be any size since it depends on the cutting die’s dimensions.
Mass production: A custom steel rule die can create multiple parts at a time, depending on the size of the part itself. This capability makes it easy to increase the volume of small, simple components.
Customization: If hard-to-find components are included in your manufacturing process, our cutting technique can create standardized parts to your specs.

American Micro Industries’ Steel Rule Die Cutting Capabilities

American Micro Industries provides a range of steel rule die cutting services.

We offer low tooling costs and never impose a minimum order requirement on our customers. Whether you’re prototyping a new product or looking to mass-produce custom die cut components, we’ll ensure your project stays within your budget. We can also provide technical consulting to help you choose an appropriate material and process for your project.

We have quality control methods for our die cutting services to ensure the results are consistent with what you and your customers demand. As your contract manufacturer, American Micro Industries offers turnkey solutions and fast turnaround times, allowing your team to start working sooner and get finished products to market quicker.

We’re happy to offer free, no-obligation quotes for any project. Call or email our office to get started today.