Complex Multi-Layer Laminating Services

Island placement works by keeping web tension steady, using servo-driven equipment, and building tooling that naturally keeps everything lined up. It’s not just about running fast; it’s about making sure adhesive placement, liner handling, and die cutting all stay in sync as the web moves.

Thin films tend to stretch, wrinkle, and shift;  that’s really the tricky part. They don’t respond well to off tension settings or liners that aren’t consistent. That’s why having in‑house laminating and process engineering makes such a difference. We can dial in tension, pick the right liner, and even add surface treatments when needed so the film behaves during placement.

Zone coating lets you put adhesive only where it actually helps. That means less waste, better compressibility (especially with foams), easier assembly, and lower cost. It’s really about getting the best performance out of the material, not just cutting cost. We use zone coating a lot when fully coating a material would hold it back.

Yep, that’s usually how it’s done. You can put PSAs down in specific areas during laminating, either with patterned adhesive or by controlling the transfer. It really just comes down to having the right tooling and good process control, which is why doing it in‑house makes such a difference.

Use deadening when you don’t want the adhesive to stick in certain spots. Zone coating means there’s no adhesive applied in those areas at all. Deadening means the adhesive is there, but it’s purposely neutralized. It’s helpful when you need full‑web adhesive for processing, but still want certain areas to release cleanly or stay non‑tacky for assembly or function.

Hot roll laminating basically gives you better flow and stronger, more consistent bonds. The added heat helps adhesives wet out properly, especially on low‑surface‑energy materials, thicker builds, or anything that needs a bit more performance. It’s also great when working with heat‑activated adhesives. We turn to hot‑roll lamination anytime cold pressure alone isn’t enough to deliver a reliable, repeatable bond.

Common deadening materials include release liners, silicone‑coated films, and specialty deadening coatings. Basically, they keep the adhesive from sticking where it shouldn’t, without affecting the rest of the part.

Extended liner means there’s extra liner beyond the edge of the part, which just makes it easier to grab and place. A shingled tab is when parts slightly overlap on the liner so pulling one tab automatically exposes the next.

If it’s set up the right way, it shouldn’t cause any issues. We place pull tabs outside the main bonding areas or in spots where they won’t interfere with how the part works. When they’re designed well, they make things easier to use without hurting performance. Issues usually come from poorly placed tabs; good converting prevents that.

If a material doesn’t want to stick, that’s usually your sign. Low‑surface‑energy materials, like certain films, foams, and silicones, often need a little help. Corona and plasma treatments both boost surface energy; the right one depends on the material and how strong of a bond you need. We use surface treatment when standard laminating isn’t quite enough.

Not forever. The effect of surface treatment wears off over time, which is why we usually treat right before or during laminating. If it’s done too early, the benefit fades before you even get to bonding.

Yes, as long as things are set up right. You can back‑score PET liners, but it takes tighter control and the right tooling since PET doesn’t act like paper. This is one of those areas where having experience and solid in‑house process control really makes a difference.