Which Custom Tape Process Is Best for My Application Needs?

Selecting the right tape converting process plays a direct role in how an industrial tape performs, how efficiently it can be produced, and how well it supports manufacturing goals, including adhesion retention, bond strength, and long-term adhesive performance. Each converting method affects cost, lead time, material yield, and part performance differently. Choosing the optimal approach ensures tape components meet specifications while aligning with production requirements.

The correct converting method also supports precision and consistency across thousands of parts. This level of control is essential for applications such as gasket seals  or shielding, where adhesion strength and dimensional accuracy are critical. Matching the application process to the material helps reduce waste by speeding processing times and optimizing adhesives and foam usage thereby improving overall material yield. From supporting prototypes to scaling and production, the right process aligns throughput and timelines with project needs.

Why Selecting the Right Tape Converting Process Matters

There is no one-size-fits-all solution when it comes to tape converting. Each method impacts cost, ease of use, and performance differently. Selecting the right process helps ensure consistent performance, and predictable results across production runs.

Precision and consistency are especially important for parts such as seals or shielding components, where uniform quality is required. Waste reduction is another key factor. Speed of assembly is perhaps the largest benefit of converted parts.  Matching the converting technique to the part geometry, assembly method, and tape material, including: double-sided tape, transfer tape, PVC tape, or single-sided construction, helps minimize scrap and protect part integrity. The right process also supports scalability. Manufacturers can move efficiently from prototyping to production while preserving material performance and maximizing yield.

Key Factors in Choosing a Tape Converting Process

Several factors influence which converting process best fits an application. Geometry and tolerance requirements are often the starting point. Complex shapes or tight tolerances may require precision die cutting or laser cutting, while simpler geometries and straight-line cuts can be handled efficiently with slitting or sheeting.

Material properties also play a significant role. Tape composition, thickness, and adhesive type influence how a material responds during cutting. Dense or thick materials may require waterjet cutting, while thin films, application tapes, or transfer tapes may die-cut cleanly.  Surface energy characteristics of the application substrates are another consideration, as adhesive performance and long-term adhesion retention depend on proper preparation and material compatibility, particularly for high-performance adhesives. Production volume and budget also affect process selection. High volumes may justify tooling investments that reduce per-part cost, while low volumes or development programs benefit from toolless digital cutting that minimizes setup time. Environmental factors such as temperature exposure or assembly conditions may further guide the choice of process, particularly when lamination or kiss-cutting supports ease of installation in battery pack, PCB assembly, or data center cooling applications.

Die Cutting

Die cutting uses a dedicated tool to produce parts and is well suited for medium to high-volume production requiring precision. This method supports tight tolerances and repeatability, making it suitable for gaskets, seals, electronics insulation, and pressure-sensitive tapes used in controlled applications where bond strength must remain consistent.

Common die-cutting formats include flat bed large format, flat bed traveling head, flat bed kiss cut, and rotary die cutting. Depending on the method, die cutting efficiently produces through-cuts, kiss-cuts, perforations, and tabbed parts that simplify assembly. While this process requires custom tooling and lead time, it delivers consistent results across large runs. Wide-format die cutting supports parts up to 62 inches and is commonly used for thermal protection and insulation components.

Slitting, Sheeting, and Spooling

Slitting converts large master rolls into custom widths, supporting applications that require continuous rolls or specific dimensions for automated equipment. Widths as narrow as 0.125 inches can be produced with clean edges that help prevent unwind issues and maintain adhesive performance.

This process is commonly used for double-sided tape, single-sided constructions, and industrial tapes supplied in roll form. Lathe slitting, rewind slitting, sheeting, and spooling support flexible volumes, long-length planetary or spooled rolls, and sheeted parts for varied application processes. These methods are best suited for straight-line cuts, and blade setup can be adjusted to maintain edge quality based on adhesive type and material thickness including high-performance PSA tapes.

Toolless Digital Cutting (Laser, Waterjet, Knife)

Toolless digital cutting includes laser, waterjet, and knife cutting methods. These processes provide flexibility without tooling delays and support early-stage development or short-run production.

Laser cutting is a non-contact method well suited for intricate parts and thin materials used electronic components. Waterjet cutting supports thick, dense, or multilayer materials using a high-pressure water cutting process that avoids thermal distorting delicate foams. Knife cutting uses a blade to produce prototypes, short runs, or large-format parts, supporting lengths up to 120 inches.

All digital cutting methods avoid tooling costs and support iterative design. These approaches can cleanly cut thicker materials without cupping and are often used before transitioning to die cutting for production volumes.

Multi-Layer Lamination

Lamination bonds multiple materials together to form custom tape constructions. This process is required when combining layers such as foams, foils, and pressure-sensitive adhesives into a single structure.

To support consistent bonding and layer alignment, lamination is performed using servo-driven laminators with heated nip rollers, liner unwinders, and rewinders. This controlled process helps maintain uniform pressure and temperature across the web, contributing to repeatable bond quality in multi-layer constructions designed for a variety of needs like thermal protection, electrical insulation, and extreme thermal cycling.

Lamination enables performance characteristics such as heat resistance, shielding, or controlled adhesion. Equipment supports web widths up to 60 inches and allows for multi-step lamination where required. Ensuring compatibility between layers, including adhesive chemistry and surface energy considerations, is essential to achieving consistent results.

Product Assembly

Product assembly services include kitting, bonding, and assembling parts to simplify integration into customer workflows. These services are useful when combining multiple die-cut components or when UL-rated subassemblies are required.

Assembly reduces internal labor, supports consistent output, and aligns with ISO 9001-certified quality management systems. Clear communication around tolerances, fit, surface preparation, and assembly details helps ensure predictable performance.

Choosing the Best Process for Your Application

Selecting the best converting process starts by matching requirements to capabilities. Tight tolerances often favor die cutting, while small runs or evolving designs benefit from digital cutting. Prototyping can begin with tool-free methods before transitioning to tooling-based processes for large-scale production.

Material type, thickness, and temperature resistance influence the decision. Thick or heat-sensitive materials may benefit from waterjet cutting, continuous roll applications align with slitting, and layered constructions require lamination. Volume and budget also factor into the choice, with tooling becoming cost-effective at scale. Understanding the application surface, surface energy, and environmental factors helps ensure reliable adhesion strength and long-term performance.

Industry Examples and Applications

In aerospace applications, custom laminates and die-cut parts support thermal shielding and insulation. Electronics applications use precise die cuts and laminated pressure-sensitive tapes for shielding and insulation in devices and enclosures. HVAC systems rely on laminated foams and large die-cut or waterjet-cut parts for duct and panel insulation. Automotive and vehicle applications use die-cut tapes, foams, and gaskets for vibration control, sealing, and automated assembly processes.

Connect with Engineered Materials to discuss the converting process that best supports your material, performance, and production requirements.