Revolutionizing Die-Cut Adhesive Application Through Automation
Die cutting is a versatile method for cutting distinct shapes from a roll or sheet of adhesive-backed materials including foams, woven and non-woven textiles, silicone, rubbers, abrasives, paper, foils, plastic, cork, and more. These die cut pieces are used in many applications such as:
- Protective films on screens or appliances
- Labels in various shapes and sizes
- Gaskets and sealing rings
- Pads
- Liners
- Sound or vibration-proofing material
- Insulating material
During assembly, these cutouts must be positioned and applied carefully in exact locations on or inside products or components. When performed manually, this kind of task can be time-consuming and prone to human error, which leads to production bottlenecks and waste. Fortunately, automation is helping revolutionize the labor-intensive process of applying die cut materials. Not only does this reduce cycle times, but it also improves the accuracy and quality of application.
Keep reading to learn more about the benefits of automating the die-cut adhesive application process.
Features of Automated Die-Cut Adhesive Applicator Equipment
Automation is best for processes and operations that are highly repetitive and prone to human error. Peeling die-cuts from a backing and applying them with precision without wrinkles or bubbles, over and over, is a strong candidate for automation in high-volume production. Specialized applicator equipment has several key features that are well-suited to this type of work, such as:
- Opportunity to add assembly aids. Converting process capabilities allow for the integration of automated assembly aids like extended liners for easy removal, pull tabs for convenient access, and zone-coated adhesives for precise bonding areas.
- High-speed operation. Automation equipment moves quickly along pre-programmed paths, and has built-in mechanisms designed to remove die cuts from backings or carrier strips efficiently. Machines also do not require breaks, and because each application is made correctly, no time is lost removing and fixing a misaligned piece.
- Precision and repeatability. Because all of the movements of the machine are pre-programmed, they are easily repeated until the machine is told to stop. Die cuts or labels are fed into the machine from uniform rolls or sheets, so the steps involved do not change from batch to batch, achieving in-tolerance placement, sometimes within 0.002 in. It’s also possible to adjust the process as designs or products change.
- Advanced automation technology. Features like motion control, sensors, and conveyance advance items into position, prepare and apply the die cut or protective film with appropriate force. Precision application means there are no distortions or bubbles. Then, the finished item is quickly conveyed out of the machine as the next one is loaded.
- Quick changeover. Many automated solutions include a menu of product options or are compatible with QR codes to call up new sets of pre-programmed instructions to switch from one component or type of die cut to another.
- Integrability. Automated applicator machines can often be integrated into an existing assembly or packaging line. In early stages of product development, they can serve as a key component in a new automated production plan. Of course, many can also be used as standalone equipment at a workstation.
- User-friendly. Modern automation equipment is designed to be intuitive, with clear graphical user interfaces (GUIs) and simple controls. Automated equipment is intended to simplify operator tasks for streamlined loading and unloading reels or stacks of die cuts, preparing a new batch of products to be labeled, or easily switching from one task to another.
Benefits of Automating the Application of Die-Cut Adhesives
If you’re looking to increase the accuracy, efficiency, and consistency of your die-cut adhesive application process, then now is the perfect time to consider automation. Benefits include:
- Less waste. Automated equipment improves the precision and quality of die cut applications, which results in fewer misaligned or damaged pieces, less waste, and less time spent removing and reapplying incorrect die cuts.
- Ease of use. User-friendly designs and GUIs reduce the learning curve needed to become proficient with the automated process and the machine. This allows personnel to feel comfortable working with it and helps them “buy in” to automation in their daily work.
- Versatility. A dedicated machine can be used exclusively for one type of product or die cut material, or it can be used with multiple shapes or types of die cuts and substrates. Fast and simple changeover makes this equipment flexible.
- Cost efficiency. Investing in a robust automated system to apply die cuts allows you to scale production or expand product offerings without compromising on quality or adding staff.
- Fast cycle times. While manual adhesive application is a meticulous, time-consuming process, automated applicators streamline the process with pre-programmed movements that prepare and apply die cuts and labels efficiently.
- Labor management. Time and labor saved due to automation allow personnel to oversee multiple pieces of machinery or be redeployed to higher-value tasks.
Contact TPC Converting to Learn More About Automating Die-Cut Adhesive Application
Since 1967, the TPC Converting team has been an innovator in protective solutions. We work with customers in industries including construction, transportation, automotive, e-mobility, and appliances, to find efficient, cost-effective adhesive products and application processes.
Contact us to learn about our die cut adhesive capabilities and how automation can help take your operations to the next level.