Flextech has a wide range of die cutting machinery that we utilize depending on the requirements of your project. We have high speed, tight tolerance Preco machines, large-platen four post machines, traveling head machines and clicker presses and are able to accurately cut an extensive variety of materials.
Foam die cutting is a manufacturing process used to cut foam materials and foam composites into custom shapes, gaskets, seals, pads, insulation components, packaging inserts, and other engineered parts. Using steel-rule dies and specialized cutting equipment, foam parts can be produced accurately and consistently across both prototype and production volumes.
At Flextech, we utilize several types of die-cutting equipment, selecting the best process based on the material being converted, part geometry, required tolerances, and production volume. Our capabilities include clicker presses for prototyping and short-run production, traveling head presses, 4-post hydraulic presses for larger parts and high-tonnage applications, inline die-cutting systems for high-volume manufacturing, and high-speed PRECO® precision die-cutting presses for components that require tight dimensional tolerances and consistent repeatability.
This combination of equipment allows us to efficiently process materials in both roll and sheet form, including foam-to-adhesive laminates, foam-to-fabric composites, foam-to-film constructions, and other multi-material composites. By utilizing multiple die-cutting technologies, we can manufacture everything from simple foam gaskets, and seals to complex multi-layer laminated components while utilizing the most efficient production method for each application.
Our die-cutting capabilities support a wide range of materials, including closed-cell foams, open-cell foams, nonwovens, technical fabrics, films, pressure-sensitive adhesives, and laminated composites used in medical, industrial, personal protection, and other specialty applications.
One of the things that sets Flextech apart is our fully integrated in-house tool shop. We design, build, maintain, repair, and modify our own steel-rule dies, allowing us to respond quickly to customer requirements while maintaining control over tooling quality and lead times. Our tooling department is equipped with SDS Automation CNC rule-bending equipment and a state-of-the-art Cutlite Penta laser cutting system used to cut die boards and tooling components. These capabilities give us greater flexibility when making tooling modifications, supporting prototype programs, and transitioning projects into production.
Whether you need prototype quantities for testing and validation prior to full-scale manufacturing, short production runs, or high-volume production, our technical sales team can help determine the right die-cutting process and tooling design for your application. The result is a dependable, cost-effective manufacturing solution for precision foam, fabric, adhesive, and composite components.
Flextech die cuts a wide range of foams, foam composites, and specialty cellular materials. With decades of experience working with foam materials, our team can help identify the right solution for applications requiring cushioning, sealing, vibration control, thermal insulation, filtration, flotation, impact protection, and enhanced comfort.
Some of the materials we commonly convert include:
In addition to individual foam materials, Flextech routinely die cuts adhesive-backed products, flame-laminated fabric and foam composites, and multi-layer laminated constructions designed to meet specific performance requirements.
Our die cutting equipment can process materials ranging from thin gasket and sealing products to thick cushioning, packaging, and protective components. Whether your application requires energy absorption, chemical resistance, thermal performance, flame resistance, buoyancy, EMI shielding, ESD protection, or long-term durability, we can help identify the material best suited for the job.
Not sure which material is right for your application? Our technical sales team works closely with customers during material selection, prototyping, and product development to ensure the final design meets both performance expectations and cost objectives.
Flextech combines decades of foam-converting experience with advanced die-cutting technologies to manufacture precision foam components for a wide range of industries and applications. From simple pads and gaskets to complex multilayer assemblies, we help customers move efficiently from product development and prototyping into full-scale production.
Customers choose Flextech for custom foam die cutting because we offer:
What differentiates Flextech from many converters is our ability to support the entire manufacturing process, not just the cutting operation. Our team works closely with customers to select materials, refine part designs, identify the most efficient manufacturing methods, and develop tooling that supports long-term production requirements.
Because we design, build, maintain, and repair tooling in-house, we can respond quickly to tooling modifications, production changes, and ongoing maintenance needs without relying on outside suppliers. This helps reduce downtime, improve responsiveness, and maintain consistent product quality throughout the life of a program.
Whether you need prototype components for product validation or millions of production parts annually, Flextech has the equipment, technical expertise, and manufacturing experience to deliver reliable, repeatable results at scale.
We look forward to an opportunity to work with you on the development of your die cut foam project.
