Custom Gaskets and Die Cuts

Web Seal fabricates precision die cut gaskets and products such as insulators, spacers and washers, for a wide range of industries, businesses and applications.  We work with your design and engineering staff to consistently meet your tolerance requirements and other specifications to ensure successful integration into your application.

A well-designed gasket entails creating a satisfactory combination of manufacturing processes, tool type, and appropriate gasket material, taking into account factors such as:

• configuration of mating component
• internal pressures
• external factors
• compatibility with chemicals and temperatures involved

We offer gaskets:

• Sized from 0.25" to 10 feet
• From low-volume to high-volume runs
• As single prototypes

While not a gasket, many applications call for a custom die-cut configuration.

A well-designed die cut involves creating a satisfactory combination of manufacturing processes, tool type, and appropriate material.

Web Seal is capable of fabricating custom die-cut shapes from a wide array of non-metallic materials. Examples of custom die cuts are vibration pads, bumpers and personal protective equipment (PPE) components.

Die Cutting Capabilities

• Highly customizable
• Low set-up cost
• Design changes without major tooling expenses
• Ability to withstand high compressive loads (2000 psi or higher)
• Help in eliminating the effect of imperfections on mating surfaces
• Expansive material selection; a nearly unlimited range of materials can be fabricated into gaskets, including cork, rubber, foam, fluorocarbons (such as Viton^TM) , Teflon^TM, EMI/RFI, and shims
• Pressure-sensitive adhesive (PSA) backings available for most materials
• Ability to supply your own sheet or roll materials for Web Seal fabrication
• Shapes in an unlimited variety of standard and custom profiles
• Shorter lead times than other seal manufacturing processes

Steel-rule cutting is the most common die cut technique.  A metal tool called a die is composed of hardened metal strips embedded into a hardwood plate in the configuration of the part.  This steel rule is attached to a press and, cookie-cutter style, punches out gaskets from material fed in.

The die room at Web Seal houses thousands of steel-rule dies, used to fabricate parts smaller than 0.25” to over 10 feet in diameter.  Web Seal has the capability to fabricate a variety of volumes and sizes. Steel-rule dies are the most cost-effective tooling but other options are available.

Learn more about custom gaskets and die cuts fabrication:

Die Cutting

Kiss-Cutting

Laminating & Slitting

Lathe cuts are a type of sealing device that is most effective:

• in static applications
• in applications requiring tighter tolerances
• for high volumes

Lathe cut gaskets can be fabricated out of any elastomer. Inside diameters (IDs) as small as 0.030” are possible.

• Inside diameters (ID) from as small as 0.030”
• Ideal for non-standard seal requirements, with unlimited variety of cut and wall thicknesses
• Closer control of tolerances than die-cut seals
• Less expensive than molded alternatives
• Minimal or no tooling costs
• Virtually zero waste in manufacturing process eliminating flash, parting lines, centers or concavity on sides or sealing surface
• Can be produced from any elastomeric material

Several different processes can be used to manufacture lathe cut components. The most commonly used process involves wrapping an uncured elastomer on a mandrel to produce the required ID. The rubber is then exposed to high temperature in an oven to cure it. Grinding the outside of the lathe cut provides the proper wall or outside diameter dimension. The ground extrusion is then cut to the specified thickness with a knife as the mandrel turns at high speed.

This low-temperature, precision method uses high-pressure water to easily produce quality parts with minimal tooling.  In place of dies, molds, or other tooling, the hydro-cutting process uses a CAD file that precisely positions a nozzle that forces out a stream of water at very high pressure.

Web Seal can offer waterjet parts for a wide range of applications, using a nearly unlimited choice of non-metallic materials in a variety of thicknesses.

Waterjet cutting is particularly effective for:

• low volumes or large gaskets, when eliminating tooling charges can offset production costs
• tight tolerances
• custom shapes and more complex designs without the cost of tooling
• smooth finishes and precision edges
• material cost savings through improved yields by nesting parts
• experimenting with design options
• rapid prototyping

Maximize yields

• accuracy of cutting results in little to no material loss
• precision alignment allows for parts to be tightly nested for better material yield

Assure accuracy

• technique provides exceptional levels of precision and accuracy, with clean cuts
• waterjet cutting provides tighter tolerances than die cutting with less compression distortion

Create complex parts

• waterjet cutting can handle small inner radii, tight angles and sharp corners, odd geometries, complicated curves, intricate holes, narrow walls, and cutouts close to other cutouts, which can be difficult to achieve with a steel-rule die

Test prototypes and parts

• waterjet cutting can be a cost-effective way to test designs before tooling is created, eliminating costly modifications or multiple tools
• process offers quick turnaround for testing schedules

Produce low-volume runs

• small-volume parts can often be produced more cost-effectively with waterjet cutting rather than creating expensive tooling

Maintain material integrity

• waterjet parts have cleaner edge quality because of less compression distortion
• high structural reliability is maintained because material is not subject to heat or stress in waterjet cutting
• the waterjet process cuts materials that cannot be produced by laser cutting

Reduce production time

• individual parts can be produced faster with multiple cutting heads used simultaneously
• smoother waterjet finishes eliminate the need for secondary finishing

Work with a wide range of specs

• Web Seal can provide waterjet parts in all types of materials
• tight nesting of even small parts using stiff materials can be achieved
• the waterjet process can cut materials too thick for die cutting and maintain excellent tolerances
• oversize gaskets can be accommodated

Save money

• Waterjet can offer cost savings from the elimination of tooling and improved material yield

A waterjet machine forces a high-speed stream of highly pressurized water (60,000 PSI or greater) through a small nozzle (usually a 0.0004” opening).

Using a Gantry-style machine set-up, the cutting nozzle is controlled by computers or CNC systems and its position is consistently monitored to ensure accuracy.  The process produces exceptionally clean cuts with little to no compression distortion, even with materials up to 4”-6” thick.   Large table surfaces allow for cutting oversized parts.

The remarkable accuracy of the technique allows parts to be nested and achieves tolerances of ±0.005", depending on type of material and thickness.