A technical process guide for a precision die cutting manufacturer serving aerospace, automotive, electronics, and medical device industries. The content transforms a 75-year-old company’s operational expertise into searchable, educational material that captures engineers during the specification phase.
Role: Sole author Audience: Design engineers, procurement managers, manufacturing leads Results: 350% YoY organic traffic growth, top-performing content asset
Content Strategy
Industrial manufacturers often have decades of expertise locked in the heads of their operators. This guide extracts that knowledge into a structured format that answers the questions engineers actually search for — process comparisons, material compatibility, tolerance specifications.
The piece covers three primary cutting techniques:
Rotary Die Cutting
- Cylindrical dies on rotating rollers
- Ideal for thin, flexible materials (foams, films, tapes)
- Continuous roll-to-roll production
- Multiple processes in single pass (cutting, laminating, slitting)
Flat-Bed Die Cutting
- Flat dies pressing downward on material
- Handles thicker, rigid materials with precision
- Best for low to medium-volume projects requiring tight tolerances
Steel Rule Die Cutting
- Steel blades embedded in wood or metal base
- Cost-effective for prototypes and simple designs
- Versatile entry point for custom projects
Materials Coverage
The guide includes a comprehensive compatibility matrix:
Material Class Examples Preferred Method Applications Plastics PET, PVC, Polycarbonate, HDPE Flatbed, Rotary Electronics housings, medical device components, display windows Foams Open-cell polyurethane, closed-cell neoprene, EPDM Rotary, Steel Rule Gaskets, seals, cushioning, thermal insulation Rubber Neoprene, EPDM, Silicone, Natural rubber Flatbed Weatherstripping, vibration dampening, FDA-compliant seals Adhesive Tapes Double-sided, transfer, foam-backed Rotary Bonding layers, EMI shielding, assembly aids Metal Foils Aluminum, copper, steel (<0.010”) Flatbed EMI/RFI shielding, thermal management, decorative trim Technical Textiles Kevlar, Nylon, Polyester, Nomex Steel Rule, Flatbed Aerospace interiors, protective equipment, filtration Achievable tolerances range from ±0.015” for standard work to ±0.005” for precision applications with experienced operators.
Process Documentation
The five-step process flow:
Step 1: Die Design Custom die creation matching exact component specifications. CAD files translated to cutting tool geometry, accounting for material springback and kerf width.
Step 2: Material Preparation Raw material cut to manageable size, inspected for defects, adhesive backing applied if required. Material orientation marked for grain-sensitive cuts.
Step 3: Machine Setup Die installed and aligned, cutting pressure calibrated to material thickness, feed rate adjusted for clean cuts without material distortion.
Step 4: Execution Die pressed into material under controlled force. Inline sensors monitor cut depth and pressure consistency. Scrap matrix separated from finished parts.
Step 5: Post-Processing Parts removed from carrier, secondary operations applied (slitting, laminating, kitting), dimensional inspection against specifications, packaging for shipment.
Competitive Positioning
The content positions die cutting against alternative technologies (laser, waterjet, CNC routing, plasma) with honest trade-off analysis — establishing credibility by acknowledging when other methods are superior rather than overselling.
Why It Works
Engineers searching “die cutting process” or “rotary vs flatbed die cutting” are in specification mode. They need to understand the technology before they can write an RFQ. This guide meets them at that moment with the depth required to establish trust — then converts through demonstrated expertise rather than sales pressure.
The 350% traffic growth came from ranking for dozens of long-tail manufacturing queries that competitors ignored in favor of branded advertising.
Full samples available upon request due to client courtesy.