Custom Die Cut Adhesive Q&A | Strouse

The beginning of a custom die cut converting project usually goes something like this:

Here’s where it gets interesting: At this point, the converter should start asking their own questions.

As an engineering-focused converting company, Strouse’s Territory Managers are skilled in asking project-specific questions to ensure your quality and timing expectations are met. Your project relies on our accuracy, and specific information can significantly help avoid stress or complications later on. 

A reputable converter will ask you the following questions to begin a successful partnership. 

What Questions Should a Converter Ask You?

Providing your converter with crucial information can accelerate decision-making, reduce costs, and accelerate the time your product goes to market. 

1. “WHAT IS THE APPLICATION?”

Sounds basic, right? However, a proper understanding of the application is needed to nail performance goals and tolerance specs (more on those below). 

A quality converter can do almost anything IF they understand the application and how the product is ultimately being used. In other words, capabilities can be reworked and altered to meet your product’s datum point. 

We understand that not every aspect of a project can be shared due to confidentiality or intellectual property reasons. Yet, to get the full benefit of a converter relationship, it’s essential to be as open as possible about the product’s use. Developing a viable solution without knowing the part's final application can be challenging, and seemingly insignificant details may become vital once you begin manufacturing. 

2. “WHERE ARE YOU IN YOUR PROJECT DEVELOPMENT?”

Every project needs a timeline. Depending on where you are in the process, you could be designing, prototyping, sampling, validating, or even in production. 

1. If your project is already in production, your converter will want to know your motivation to switch. Switching your die cut converter or solution costs time and money, so it will be essential to understand the rationale behind that expenditure.
2. If you’re in the design phase, it’s the perfect time to test solutions before switching over becomes too expensive. We can test materials, designs, specifications, and tolerances to ensure the part is designed for manufacturability. 

In addition, tell your converter if you have a timeline regarding how quickly you expect to commercialize. 

3. “WHAT SUBSTRATES WILL YOU APPLY THIS PRODUCT TO?”

If your product has just one substrate (a.k.a., surface material), it’s relatively straightforward: Your converter needs to find an adhesive that likes said substrate. But what happens when you’re bonding two different substrates? 

Finding the right product can be especially difficult if the substrates differ vastly (for example, silicone and plastic). This may mean creating new material by combining multiple tapes to build one with different adhesives on either side.

4. “WHAT MATERIALS HAVE YOU TRIED? IF YOU’VE PICKED ONE, WHY DID YOU CHOOSE THAT MATERIAL?”

If you’ve already tested materials, we don’t need to start from square one. One of the first things a converter should find out is the journey you’ve already gone on before talking to them. This information can help accelerate the design and manufacturing process that needs to occur now.

Certain materials might be ill-suited for your application or production method. Others may be overkill—going above and beyond the project’s needs with a premium price point. Engaging with a quality converter will prevent you from buying unnecessary products and allow you to find better material alternatives for your product’s function and manufacturability.

5. “WHAT TYPE OF QUALITY STANDARDS DOES YOUR PROJECT REQUIRE?” 

Does your project need to be in a Cleanroom? Do you need 100% part inspection? Both of these cost more but ensure higher quality. However, your part may only require basic ISO 9001 or 13485 standards. Connect your quality team with your converter’s team to determine a quality plan that fits your needs and specifications.

6. “WHAT PROCESS DO YOU HAVE PLANNED TO APPLY YOUR PART?”

When a converter knows that a robot will be applying the product, they’ll design your part to withstand that stress level when applied. Parts that must be repeatable for automation can be processed on a roll with a plastic liner so the machine accepts them more easily. 

If the product is applied by hand, a tab system may speed up and improve application. Creating kits for the operators may also improve efficiency, depending on the product.

7. “WHAT TOLERANCES ARE NEEDED?”

Customer drawings often contain overengineered tolerances, significantly impacting cost and manufacturing feasibility. Our engineering team frequently asks technical teams to determine where tolerance is critical to the product and where there is flexibility. 

Part tolerances are a cost vs. value scenario. The scale varies significantly from project to project when it comes to what’s asked vs. what’s needed, and it’s the converter’s job to inquire further and combine price and efficiency for each successful project. For instance, a project’s critical tolerances dictate its manufacturing process. If a tolerance can’t be met with rotary die cutting, it must be done using flat bed or laser die cutting, which could be slower and more expensive. 

8. “WHAT ARE YOUR PROJECTED QUANTITIES?”

Imagine visiting the bank to withdraw some cash, but when the teller asks how much, you say: “I don’t know.” Part quantity is another essential component of product design and material selection. It allows converters to design more cost-efficient and effective production plans. 

9. “ARE YOU LOOKING TO SCALE?” 

Many converting solutions are designed for jobs of a finite quantity, so you’ll want to clarify any goals for scaling up your product. You may not know your projected quantities yet, but this question will get you looking ahead to build a production timeline. 

Part of the project timeline involves the material planning aspect of the process. How many rolls do you anticipate ordering? Do you foresee a monthly or annual supply schedule? These are important questions to consider when examining quantities. 

9. “ARE YOU OPEN TO NEW IDEAS?”

A converter that knows a product's origin, application, and end use might spot an opportunity for improvement.

Take this paint masking application as an example: 

A customer uses roll after roll of masking tape (each costing $1) to mask a vehicle before painting. The converter may suggest an alternative: a specific die cut solution kit that costs five times as much as the tape rolls. 

Despite the higher cost, the masking kit allows two people, instead of multiple, to peel apart and apply tape much faster. Although this value opportunity costs more on materials, it saves on labor, lowering the total cost.

Prepare for Die Cut Production

If you’re talking to a flexible material converter, you likely have many other questions about the converting process. Luckily, we’ve got some resources to help you get started. 

Lastly, you can check out our Learning Center or reach out for more information on converting, materials, and project design.

Originally published: February 14, 2023