Rotary die cutting is a manufacturing process that is used in the construction of or the attachment of medical devices to cut shapes out of various materials including foams, films, liners and carriers. This provides the option for precision die cutting of multilayer components, that is crucial for all medical device parts.
Bringing materials with differing behaviours together in one construction is very complex but rotary die cutting can provide the necessary results. BDK has extensive expertise in processing adhesive and non-adhesive materials for custom die-cut components in medical applications.
Understanding Rotary Die Cutting Technology
Rotary die cutting provides key benefits during manufacturing including speed, accuracy, repeatability and scalability. This is particularly useful for high-volume medical production in contrast to flatbed die cutting because it provides a faster pace, precision, and cost-effectiveness. Rotary machines are also capable of continuous roll-to-roll cutting which increases throughput. In contrast, flatbed machines are good for thicker materials or lower volume runs.
Key Material Categories Suitable for Rotary Die Cutting
There are lots of different materials that are suitable for rotary die cutting. Some of the key examples include:
Pressure-Sensitive Adhesives (PSAs)
The most common PSAs used in medical applications include acrylic, silicone, polyurethane and rubber-based adhesives with different options such as single or double sided tapes both linered vs unsupported transfer adhesives. Rotary die cutting is required for manufacturing wound care or ostomy dressings, diagnostic products, wearable devices as well as electrode assemblies.
Films
Films including polyurethane (PU), polyethylene (PE), polyester (PET), and polycarbonate can all be processed using rotary die cutting. This can be used for barrier layers, sensor substrate and flexible electronics. It is important to note that films may not need to be medical grade as it depends on the application as well as where films are used.
Foams
Foams can either be open-cell or closed-cell foams and include PU foam, PE foam, and silicone foam. This material is key for compression, cushioning and skin contact application, with the common uses including gaskets, contact layers and isolation barriers.
Nonwovens & Tapes
Examples of nonwoven tapes, include spunlace, meltblown, spundbond, wet laid or thermal bond. There are also options of double-sided and transfer tapes for multi-layer assemblies. Custom lamination is available using rotary die cutting with adhesives for multi-functional components.
Liners & Carriers
Liners and carriers include paper, filmic and specialty liners that are used in multilayer converting. They have a role in process control, release properties and final device functionality. Rotary die cutting is suitable because it can leave the liner intact resulting in kiss cutting where the die only touches the top layer.
Material Considerations in Rotary Die Cutting
There are various considerations for rotary die cutting and whether or not it is the right choice for your material. For instance, you need to think about material thickness, flexibility and tolerance control as these attributes impact precision and repeatability. Sometimes flatbed die cutting may be more beneficial.
Furthermore, adhesive properties including tack, release force and shear strength can all affect die cutting performance. That’s why it’s important to manage adhesive ooze and edge definition during high-speed cutting.
BDK’s Expertise in Converting Die-Cut Medical Materials
BDK has custom tooling for precision die cutting, cleanroom converting capabilities and process validation, suitable for a wide range of medical equipment manufacturing requirements. We provide efficient adhesive solutions tailored to your application, so contact us today to discuss your custom precision die cutting requirements.