Silicone rubber die-cut gaskets play a vital role in sealing, cushioning, and insulating components across a wide range of industries, including electronics, automotive, aerospace, and medical. Their versatility, durability, and resistance to extreme temperatures make them a preferred choice in critical applications.
In this blog, we will explore what silicone die-cut gaskets are, how they are manufactured, the best cutting methods available, their applications, and why Elastostar Rubber Corporation is a trusted name in this domain.
Table of Contents
What Are Silicone Rubber Die-Cut Gaskets?
When it comes to making outline designs for die-cutting, machined tools are being used. In this case, a gasket is used in conjunction with a hydraulic press to shear material from large rolls of raw material. This type of raw material could be anything from silicone rubber to metallic materials. This type of process is similar to a hole puncher, generally used for office paperwork. The press will house the die under the hydraulic press. While operating, it will press itself into a material, cutting to the die design that is suitable for your desired application.
These types of dies are made of steel rules, which have a long lifespan and are suitable for mass production. Die cutters could easily produce thousands of silicone rubber tubes, gaskets, and seals per hour. It has a low tooling cost and is great for high-volume orders. Design tolerances can range from a tenth to a thousandth of an inch from the desired design.
Elastostar Rubber Corp is a leading die-cut gasket manufacturer in the USA with a wide array of capabilities and techniques focused on bringing the best value to customers. Here are some benefits you will only get with Elastostar Rubber Corp.
- CNC Die Cutting
- Large Die-Cut Footprint
- Cost-effective steel rule die-cutting
- Machined solid steel dies for complex and delicate parts
Which is the Best Die Cutting Method?
There are various die-cutting methods utilized to make die-cut gaskets. The best and most effective manufacturing gaskets will depend on acceptance, quantities, and the type of rubber materials being used. Elastostar Rubber Corp will work with engineers to design the optimal converting method, making it cost-effective and improving handling.
The Applications Engineers at Elastostar Rubber Corp will help you evaluate the design for manufacturability and minimize manufacturing costs. Minor design changes will surely save you thousands of dollars in product costs.
Silicone Rubber Die Cutting Process
Silicone die-cutting involves using a steel die or digital cutting tool to press or slice the desired gasket shape out of a sheet of silicone. Here’s how the process typically works:
- Design Phase: Engineers create CAD drawings of the gasket’s shape, dimensions, and tolerances.
- Material Selection: The appropriate silicone grade (standard, medical-grade, high-temp, etc.) is chosen.
- Tooling: A steel-rule die or CNC cutting tool is prepared.
- Cutting: The silicone sheet is placed in a hydraulic press or digital cutting machine to create precision cuts.
- Finishing: Any trimming, adhesive lamination, or inspection is carried out before packaging.
This process is ideal for high-volume production due to its repeatability, speed, and cost-effectiveness.
High Speed Die Cutting Gasket
Automated Die cutters are generally used for relatively less, thin die-cut gaskets that have med-level volume. Die-cut gasket ranges from 0.25 square or round to 12 square. The flatbed die cutters are capable of cutting with adhesive on the side. Fast cutting occurs when the die blade cuts through the gasket material without cutting the adhesive line.
CNC Gasket Die Cutting Unit
Elastostar Rubber Corp’s CNC cutting unit is naturally utilized for die cutting mid- to large-sized gaskets. With its enhancing software, constant feed belt, and faster hit rate, the CNC unit is used for larger rubber gaskets with mid-level volumes (200,000 – 4500,000 per year).
Die Cut Gasket Applications
Elastostar Rubber Corp specializes in die-cutting custom silicone rubber gaskets for various applications and industries. The following are some examples of custom die-cut gaskets and their uses:
- Die-cut adhesive LED gaskets
- Die-cut LCD bezel gaskets
- Die-cut battery pads
- Die-cut radome gaskets
- Die-cut eco-friendly gaskets
- Electronics: LED lighting gaskets, display bezels, and battery pads for insulation and sealing.
- Automotive: Heat-resistant seals in engine components and dashboards.
- Medical Devices: Biocompatible seals for diagnostic equipment and surgical devices.
- Aerospace: Vibration-damping gaskets for cockpit and fuselage systems.
- Industrial: Gaskets for pumps, compressors, and control panels.
Custom silicone gaskets can also be produced with adhesives, dual durometers, or fabric reinforcements depending on the end-use environment.
Why Choose Elastostar Rubber Corporation?
Elastostar Rubber Corp is a leading manufacturer of silicone gaskets and seals in the USA, offering advanced die-cutting services backed by decades of engineering expertise.
Our capabilities include:
- CNC and flatbed die-cutting
- Rapid prototyping
- FDA, USP Class VI, and ISO-compliant materials
- Adhesive-backed gasket options
- Precision tolerances from +/- 0.005″
We offer:
- Fast lead times
- Low tooling costs
- Customized designs
- Made-in-USA quality assurance
Whether you need 100 or 100,000 parts, Elastostar delivers reliable sealing solutions customised to your requirements.
Conclusion
Die-cut silicone rubber gaskets offer outstanding performance in critical sealing and insulation applications. With various cutting methods and materials available, selecting the right approach ensures cost efficiency and precision. Elastostar Rubber Corporation provides comprehensive gasket manufacturing services, ensuring consistent quality and tailored results for specific applications.
For more use and application, please contact us with your details or Email us at [email protected] or Call us at 614-841-4400. We will help you to explore more ways to utilize our products for your special purpose.
FAQs
1. What are silicone rubber die cut gaskets used for?
Silicone rubber die cut gaskets are used for sealing, insulation, vibration control, and thermal protection. They are commonly found in electronics, medical devices, automotive parts, and aerospace applications.
2. How are silicone gaskets die cut?
Silicone gaskets are die cut by pressing a sharp steel die into sheets or rolls of silicone rubber using hydraulic or automated machinery. This process cuts the gasket into precise shapes according to your design.
3. What’s the difference between CNC die cutting and high-speed die cutting?
CNC die cutting is best for larger, complex gaskets and medium production runs. High-speed die cutting is better suited for simple, smaller gaskets that need to be produced in high volumes. Elastostar offers both methods based on your application.
4. What are the benefits of using silicone rubber for gaskets?
Silicone rubber offers excellent flexibility, temperature resistance (hot and cold), chemical stability, UV resistance, and durability. It performs well in extreme conditions and is often used in food-grade and medical applications.
5. Can die-cut gaskets include adhesives?
Yes, silicone gaskets can be die cut with adhesive backing. Pressure-sensitive adhesive (PSA) helps with easy peel-and-stick installation, especially in electronics, display seals, and automotive dashboards.
6. What industries commonly use die-cut silicone gaskets
Industries such as automotive, aerospace, medical, food processing, consumer electronics, and industrial manufacturing commonly use custom die-cut silicone gaskets for precision sealing and insulation needs.
7. How accurate is the die-cutting process?
The die cutting process can achieve tight tolerances, often within ±0.005 inches. Elastostar ensures high accuracy and repeatability, even for intricate or delicate gasket designs.
