OK, here’s the short story: Die cut adhesives are extremely versatile and can solve business challenges in a variety of industries.

Nice (and true), but not very exciting. What’s really fun is hearing about the unexpected ways that die cut adhesives are being used; the solutions that definitely do not immediately pop to mind when you hear “adhesive applications.”

Before we jump in, feel free to read some great background on adhesive tape products and materials, how they’re replacing mechanical fasteners, and the flexibility and durability of high bonding 3M VHB tape.

Why Custom Die Cut Adhesives?

This will only take a minute (and then we’ll move onto the surprising applications). It’s not enough for us to celebrate odd and interesting ways to use custom die cut adhesives. We need to explain their specific advantages. Here we go!

• In our previous quick comparison of liquid, spray, film, and tape adhesives, we explored how temporary bonds are only available with die cut adhesives.

• The stress, or force, put on an adhesive bond is dispersed evenly along the entire bond. This stress distribution minimizes concentrated stress points, so there’s less failure.

• Die cut adhesives create secure physical seals between components, and they can expand and contract as temperatures change.

Looking good has never been more important, which makes die cut adhesives even more valuable as they create tight, low-profile connections that are clean and sleek.

• Being able to bond a wide range of items (and surfaces that aren’t the same) is a powerful advantage of die cut adhesives.

• Accuracy, efficiency, and consistency are all benefits of automatic adhesive dispensing, a strength of die cut adhesives.

• The “custom” part of “custom die cut adhesives” shouldn’t be overlooked. Converting into custom sizes, shapes, and formats can make assembly processes easy. More on this later!

6 Surprising Applications of Custom Die Cut Adhesives

1. Truck Panel Assembly
Mechanical fasteners have been used for decades in many industrial applications. On one heavy-duty truck panel, heavy rivets (which created stress points, slowed assembly, and corroded over time) were replaced by a pressure sensitive adhesive tape.

2. Electric Car Battery
Adhesive wasn’t transferring to the brittle and layered mica shields in a battery connection assembly process. A feasible, cost-effective solution was created using die cut adhesive. Read more about this solution for Tesla Motors.

3. Water-Resistant Video Camera
A die cut adhesive was used to not only bond multiple components within a water-resistant video camera, it also helped prevent water leakage.

4. Inkjet Cartridge Microchip
An inkjet cartridge’s performance relied on securing a microchip, yet the manufacturing process required an upgrade from hand-assembly to an automated solution. Explore the full Lexmark story here.

5. Airport Terminal Ceiling
The construction industry regularly uses die cut adhesives for both temporary and permanent applications, from building large highway signage (under extreme weather conditions) to holding up nearly five tons of mirrored ceiling in an international airport terminal.

6. Army Vehicle Painting
A custom masking kit made of die cut adhesive was used to solve a complex, costly, and slow painting process during vehicle refurbishing. Instead of multiple people taking hours to apply rolls of masking tape, a kit (even at five times the cost of tape) is a cost-effective solution because it’s applied by only two people very quickly. See how Humvee production doubled.

And, that’s just a start! Here are some additional applications of custom die cut adhesives:
• Continuous glucose monitoring
• Drug dosing
• Hair removal
• Face lifting
• Gaskets for weight loss devices
• Scar reduction
• Incontinence management
• Sperm separation
• Snoring mitigation
• Body marking for CT and X-ray scans

A Trusted Converting Partnership is a Treasured Thing

When it comes to converting custom die cutting adhesives, nothing’s more valuable than a trusted partnership. A full-service converter helps evaluate a project from top to bottom and determine what die cut adhesive solution will work best. They consider function, material, design details, budget, and more to most efficiently go from rough sketches to reliable solutions.

Choosing an adhesive converter can be intimidating. Even if you have a current relationship with a converter, you may not understand how to evaluate their performance. Make sure you’re getting maximum value by reviewing these 11 questions you should ask a converter.

The best converters should also be asking you specific questions, including how the product will ultimately be used because they know the application (whether surprising or not) drives a custom die cut adhesive’s success.

Speaking of converting, you’re invited to learn more by reading our Flexible Material Converting Q&A Guide. It features common questions asked of adhesive converters and their answers. Need help now? Call Stouse today (800)-410-8273, or ask an engineer!

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Scott Chambers

Written by Scott Chambers

Business Development Manager for Strouse Scott graduated from Coastal Carolina with a degree in Business Management. He then attended the University of Baltimore School of Law earning his JD in 2016. He passed the bar later that year, and he started working for Strouse in 2017. Scott is in charge of marketing and business development in addition to being Strouse's In House Counsel.

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