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When designing a die cut gasket for a performance application, it’s important to start the process by talking to an expert. An expert will help walk you through the specs, gasket design, and application considerations to guarantee your die cut gasket will function as intended. This one-on-one consultation will also ensure you’ll receive the right die cut gasket on-time and on-budget so you’re not stuck with lengthy delays or working out of the scope of your budget.
Die cut gaskets are used for a variety of applications, with some of the most common uses being environmental seals and EMI shielding.
While there are many gasket manufacturing methods to choose from based on your application needs, the die cutting process offers a variety of unique benefits:
• Fast gasket production
• Low tooling and labor costs
• A wide selection of material options
• Automated manufacturing techniques
• Suitable for large and small parts
• Easily customizable
But what happens when your die cut gasket isn’t designed for success? The result can be costly and potentially detrimental to the application. Before specifying your next die cut gasket solution, make sure you don’t make one of these common mistakes.
Common mistake:
• Forgetting to consider bolt hole position constraints when designing a die cut gasket.
Solution:
• Through one-to-one consultations and a collaborative design/manufacturing process, an expert converter can identify potential manufacturing issues early in the design process. Early supplier involvement in the design process can help reduce manufacturing issues, which would cause costly project delays.
• If holes must be placed at the very edge of the gasket, consider an alternative manufacturing method like waterjet cutting.
• Potentially, specify an open slot instead of a hole.
• Think about using a thinner gasket material to reduce the thickness of the wall between the hole and the edge of the gasket.
The Real World:
• We’ve seen it many times over the years, gaskets drawn to perfection, with the exception of the one hole placed too close to the edge! Your typical steel rule die needs both punches and steel rule to properly cut a gasket with holes. We run into problems when there’s not enough room between the hole punch and the steel rule to eject the gasket material from the die.
• The hole placement issue has been addressed in the past through a variety of solutions including revising the hole location, switching to an alternative manufacturing method such as waterjet, or molding the gasket.
Solution:
• A quality system certified to an international standard, such as ISO9001, can help you determine if your supplier has documented processes in place to ensure product quality.
• Is your gasket supplier a cultural fit for your organization? What happens when there’s a production or quality issue? A supplier with authentic references and documented values can help determine if they’re a good fit.
• Ask about the supplier’s commitment to basic manufacturing concepts like 5S and Lean. Do they place value in a clean and well organized manufacturing facility?
• Does the supplier have a process in place to ensure expired adhesives aren’t being used to make your gaskets? Be sure to ask about their PSA (adhesive) expiration process!
Common mistake:
• Die cutting tolerances are a function of material type, part features, tool type, and production techniques. The process of manufacturing a die cut gasket is very different than machining a metal part and requires much wider tolerances.
Solution:
• Strive for tight cut tolerances, but understand the cutting process and material limitations. Acceptable tolerance levels can typically be agreed upon by consulting with die cutting experts who understand how to balance gasket fit, form, and function to processing capabilities.
• Ask your converter about alternative gasket manufacturing methods such as waterjet or CNC digital cutting if standard die cut tolerances aren’t acceptable. Cut tolerances on a high-quality waterjet can be as tight as .005” in some applications.
The Real World:
• We’re super impressed by the tolerances we can hold on aluminum parts, but we prefer to leave machining tolerances to the metal guys! Rubber by its very nature is pliable and deflects when cut with a steel rule die. It’s not uncommon for mechanical engineers designing rubber gaskets to include default CAD system tolerances on their gasket drawings. Past experience tells us correcting drawing tolerances can delay a project anywhere between a few days and a week. Most gasket converters who operate under an ISO9001, or better, quality system will ask their customer to update the tolerances on the drawing before starting production. Our tolerance tables can help engineers correctly specify tolerances, avoiding exceptions being taken on quotes, or production delays.
Solution:
• Choosing the right adhesive is one of the most important decisions you can make when detailing the specifications for your gasket. Make sure you (or an expert) take temperatures, adhesion strength, life expectancy and more into account when specifying an adhesive system.
• Ask your converter for transparency when they recommend a private label PSA. What makes the converter think their private label product will work in your application? Companies like 3M and Avery have spent millions of dollars on research and development over the years. Should you consider leveraging their R&D in your application?
• Remember to consider both adhesive surfaces when trying to specify a PSA. The adhesive will need to stick to the seal as well as the mounting surface.
• Many name brand adhesive manufacturers, like 3M for example, have lower cost alternatives. Point being, you might be able to use a high-quality 3M PSA and still meet your cost target!
