Rapid Prototyping

Yes, we have multiple means of dieless cutting to support various types of materials, methods, and geometries of parts. By having multiple capabilities, it enables us to do a wide variety of prototypes for our customers and provide more value as a supplier. 

 Yes. As die cutters, we understand that most parts we manufacture ultimately integrate with another component or assembly. Knowing the end use helps us understand the intricacies of the part and identify additional value-add opportunities. This allows us to support our customers with a more comprehensive, true manufactured solution.

We accept most of the standard CAD formats on the markets today. For 3D geometries, STEP files are preferred. For 2D geometries, dxf and dwg are preferred. 

Lead times for prototypes depend on several key factors. We understand how critical prototypes can be—often serving as the linchpin for an entire project—and we work hard to support the urgency that comes with that. To enable quick‑turn requests, we reserve capacity on our dieless cutting machines specifically for prototyping.

In most cases, the longest lead-time driver is material availability. If the required material is in stock and we have the customer design, we can sometimes produce same‑day prototypes. Otherwise, lead time typically depends on receiving sample materials from our suppliers, which is generally around one week. 

Again, it really depends on the part and the overall scope of the prototype. For relatively small parts (under 6”) where we can utilize sample rolls from our material vendors, and when the requested quantities are low (fewer than 20 pieces), MOQ is generally not an issue. MOQ also isn’t typically a problem if we already have the required material in stock. It becomes a factor when the prototype involves larger batch sizes (50+ parts) or requires a highly specific material that we’re unable to source in sample form.

Yes. We leverage our position as a 3M Preferred Converter, Avery Dennison AdVantage Partner, and Rogers Preferred Converter as well as strong relationships with other leading material manufacturers to access material quantities that smaller die cutters cannot.

Yes! We can achieve the same result with digital cutting as we can with hard tooling, but the methodology of getting there is quite different. The prototyping approach is somewhat more dependent on the material, but in most cases, we can replicate many of the same part features that would normally be produced with discrete tooling.  

The short answer is that there is not really a maximum number of parts for our prototyping services and digital cutting machines. That would all depend on part size, material availability, and other factors. The longer answer is that there comes a point when digital cutting is no longer cost effective. Because the process is much slower than traditional rotary cutting or platen die cutting, longer runs quickly become inefficient.  As a general rule once we get close to the 50-100+ piece volumes, from a time perspective, it starts to make more sense to pivot to die cutting.  

Because we have so many cutting options, we can fabricate prototype parts in a broad range of sizes – from sub 1" on the low end up to 10’ x 5’ on the high end.  In general, machine limitations begin to appear when shapes or features approach 0.0625". We can sometimes accommodate smaller or more intricate details, but this is typically the point where other methodologies should start to come into play.