Die-cut Components | US Manufacturers | Melrose

Quality Die-Cut Components from an Experienced US-Based Manufacturer

As more and more new devices enter the market, the need for high-quality die-cut components increases. Our components are made of durable non-printed materials and cut into different shapes to address specific issues such as electrical insulation, sound dampening, EMI shielding, gap filling, and more. 

You can find die-cut components developed by Melrose in a wide range of applications, from tiny mobile devices to large airplanes. We have decades of experience in manufacturing die-cut components and offer expert material and design advice to our clients.

Experienced die-cut components manufacturer

Our experts have years of experience in the design and manufacturing of die-cut components – they can address practically all unique die-cut projects. Thanks to extensive industry experience in electronics and delivering components to the most demanding industries, the Melrose engineering team can tackle your design challenges with a broad range of die-cut fabrication methods and materials, getting your product into production faster. 

To deliver outstanding value and help you achieve compliance, we hold several certifications like AS9100D.

What are die-cut components?

Designers and engineers are always seeking new and creative ways to improve the appearance and functionality of their products. External elements such as dust, moisture, and severe temperatures may affect the device’s functionality easily.

Apart from addressing these environmental factors, engineers must deal with a variety of design challenges such as reducing friction between two components, blocking EMI emissions, and keeping the device from overheating.

This is where die-cut components come in.

Die-cut components are made of non-printed materials and cut into various forms to address the specific challenges facing your device. They fix issues related to thermal management, sound dampening, gap filling, sealing, EMI shielding, electrical insulation, and bonding. You can find die-cut components in a great variety of products, from smartphones and household appliances to industrial controls and massive airplanes.

Benefits of Die-Cut Components

1

Noise dampening

If you’re looking to eliminate Buzz, squeak, and rattle (BSR) or any other unwanted noise from your device, die-cut components are the solution. BSR still poses a challenge to many industries, including automotive, electronics, aerospace, and more. Whether a washing machine or a cooling fan, the moving components may cause friction and damage these parts over their lifetime. Die-cut components minimize noise, vibration, and harshness to ensure greater performance and longevity of devices.

2

Thermal management

As electronic devices are becoming smaller than ever, heat dissipation becomes a challenge. Without a proper outlet, they might suffer from failures caused by spikes in internal temperature. Die-cut components can be used to dissipate the heat from its source and lower the overall temperature of the device. We can integrate thermal interface materials (TIM) into devices to streamline heat transfer away from the heat source and eliminate this problem.

3

EMI and RFI Shielding

Electronic devices emit electromagnetic (EM) and radio frequency (RF) waves that may interfere with one another, damaging sensitive equipment nearby. The damage can range from a temporary performance glitch to data loss. EMI emissions can become life-threatening when present in medical or military equipment. Die-cut components help devices to comply with electromagnetic compatibility (EMC) standards.

4

Bonding

When developing a device, you may need to bond two substrates together. This might be challenging if they have different textures and surface energies. One solution is Clamshell Uniquethe Using mechanical fasteners like screws, nuts, or bolts. But they’re visible and deform under stress or loosen over time. Die-cut components are the best alternative to mechanical fasteners or liquid adhesives that present several problems affecting the device’s lifecycle.

5

Gasketing and Sealing​

Engineers cut gaskets into specific shapes that are inserted between two surfaces to offer a mechanical seal. Used for sealing and gap-filling, gaskets can be made of rubber, silicone, sponge, plastic, foam, and foil. This is one of the most common applications of die-cut components that are used to seal surfaces to protect devices against elements such as moisture.

Popular die-cut components

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Gaskets and Seals

Gaskets and seals are critical layers between elements of your device that ensure its optimal operation in any kind of environment. They are commonly made of foams (including VHBs), neoprene, sponges, or rubber.

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EMI and RFI Shielding

Shielding from EMI and RFI is becoming increasingly necessary in today's technological environment. These die-cut component applications guarantee that your equipment functions correctly.

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Spacers

Spacers are frequently added at the last minute to a design, but they can be a significant component that boosts the functionality of your device. Our engineers can assist you in designing and manufacturing unique spacers from a variety of materials.

Additional die-cut components

Sound dampeners

Double-coated adhesives

Thermal materials

Insulators

Electrically conductive adhesives

Our Manufacturing techniques

At Melrose, we employ different types of tooling and processes to offer the best method matching the unique needs of every project. Here’s an overview of our techniques.

Clamshell press

This method allows cutting materials using a steel rule or chemical etch die.

Laser cutting

Our engineers use this technique with materials such as polycarbonate, polyester, acrylic, foam, and all kinds of formex materials.

Plotter cutting

The plotter cutter cuts materials with a little blade, while the router cuts larger materials, including acrylic, polycarbonate, vinyl, polyester, and aluminum.

Rotary cutting

This technique uses a rolling cylindrical anvil that houses the die tool and cuts bits from the input material as it rolls. Rotary cutting applies to both thin and thick substrates – from 25 mil foams to 5-7 mil polyesters and polycarbonates.

Water jet

Using this system, our engineers can cut materials with a high-pressure jet of water. This method allows cutting all the materials that a last can cut – but also much thicker substrates.

When achievements say more than promises

Fast shipping

We keep a permanent stock of basic products. That’s how we’re always ready to meet the needs of our customers. No long waiting times, no delays. The Melrose team is always there to make sure your company is ahead of the game.

Tailor-made solutions

Whatever feature combination you need, we can deliver it to you. Create your product by choosing various parameters. Get in touch with us, and we will start the customization process within 24h of receiving your order.

Modularity

Thanks to our unique modular system, we can offer the same display size in different configurations and adapt it to any project by easily upgrading the display without changing the product design.

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