Tape Converting Techniques: How We Customize PSA Tapes for Your Benefit
Custom fabricated pressure sensitive adhesive (PSA) tapes offer a range of benefits that can significantly enhance your assembly process, product design, and overall bond performance. By working with the right adhesive tape converter, your adhesive tape products can be tailored to meet the specific needs of any application, from electronics and automotive to construction and beyond.
How does custom tape converting improve your assembly process and end products?
Precision and Repeatability
Custom fabricated PSA tapes can be cut to the exact dimensions and shape required by your application. This precision eliminates the guesswork and variability associated with manual cutting during assembly, leading to more consistent results. Every PSA tape part is identical to the last, maintaining consistent quality across production runs. This repeatability is crucial when uniformity is key to product performance and customer satisfaction.
Enhanced Product Performance
There’s two highly effective ways to increase the performance of a bonding solution: choose the right PSA tape and have it custom fabricated to fit your application. Selecting an adhesive tape with the right properties—thermal conductivity, temperature performance, UV resistance, etc.—for the intended surface is only half the battle. Converting those PSA tapes to ensure maximum coverage and minimal handling will also significantly improve the overall durability and longevity of the bond.
Cost Savings
PSA tape customization allows for the most efficient use of materials. Converted PSA tapes are produced to the exact size needed for the application, thus reducing material waste in production. This is especially beneficial for high-cost materials and large-scale production. In many cases, there is an upfront cost for tooling, but generally that is not significant in the cost of the part over time. Moreover, with smart engineering and the opportunity to nest parts, scrap in the converting process will be minimized.
Simple and Fast Application
Custom fabricated tapes are designed for easy application, often coming in nested parts, on rolls, as kiss cut part to facilitate quick placement without the need for additional tools or equipment, and with liner tabs to provide faster production. This simplicity of application significantly speeds up the assembly process, allowing for faster production times and the ability to meet tight deadlines without sacrificing quality.
The precision and efficiency of custom PSA tapes also mean less time is spent during application and on rework and adjustments. This can help you increase production and further drive down per product manufacturing costs.
Hybrid Materials
By laminating different materials together, converters can combine the best properties of each material to meet specialized requirements and create short run custom tape products. This might include single sided foam tapes, shielding layers for insulation, vibration damping, moisture barriers, or other functionality. This gives you the ability to innovate and solve complex challenges with a single adhesive solution.
The Most Common PSA Tape Converting Methods
Die Cutting
Die cutting is a precise fabrication process used to cut pressure sensitive adhesive (PSA) tapes into specific shapes and sizes. This method involves using a die—a specialized tool—to stamp out tape pieces from a larger sheet or roll. Die cutting can be tailored to produce a wide range of shapes, from simple circles and rectangles to complex, custom designs, making it a versatile solution for various applications.
There are three types of die cutting:
Rotary die cutting: involves cylindrical dies mounted on a rotary press. As the PSA tape feeds through the machine, it passes between the rotating die and an anvil roller, which cuts or perforates the material into the desired shape. The process is continuous, with the material moving at a consistent speed through the machine. The process allows for complex lamination, slitting, and die cutting to be performed in one operation.
Flatbed die cutting: involves a flat, stationary or traveling head die that presses down on a material to cut it into shape. This method may use a hydraulic press or other mechanisms to apply the cutting force.
Inline die cutting: utilizes a press-based part stamping mechanism coupled with a reel to reel unwind and rewind to punch out shapes from thicker materials. Parts can be kiss cut onto a release liner for easy application.
The benefits of die cutting PSA tapes include:
Superior customization of simple or complex shapes
Efficient material use (low waste)
Very repeatable
Tight tolerances within microns
Scalability of production
Slitting and Spooling
Slitting is a process where large rolls of PSA tape, known as master rolls or jumbo rolls, are cut into narrower widths according to specific requirements. Slitting allows for precise control over the width of the tape, ensuring that the final product meets exact specifications for your intended use.
Spooling is the process of winding cut or slit tape onto a spool or reel in long lengths, creating a larger roll without the standard core in the middle. This technique is particularly useful for applications that require continuous use of the same tape without interrupting the process by having to change out tools or materials. It’s also more convenient for the long-term storage of PSA tapes.
The benefits of slitting and spooling PSA tapes include:
Good for narrow width requirements
Ability for non-standard widths
Fast turnarounds
Convenience
Reduced change over and downtime during assembly
Cutting PSA Tapes
Laser cutting, waterjet cutting, and knife cutting are distinct PSA tape converting processes used to cut the materials based on specified dimensions. Each technique offers unique advantages and is chosen based on the material properties, desired precision, and the specific requirements of the application. Each style of cutting offers its own advantages:
Laser cutting: uses a high-powered laser to achieve a precise and clean cut. It offers high precision, fast processing, and complex shapes. However, the heat generated is not suitable for all materials.
Waterjet cutting: utilizes a high-pressure stream of water, often mixed with an abrasive material, to cut through a variety of materials. It offers clean edges and is ideal for cutting rigid or thick foams or 3 dimensional shapes.
Knife cutting: involves using a sharp blade, router, or oscillating knife to mechanically cut through materials in pre-programmed patterns. It offers good precision and flexibility as well as no upfront tooling costs.
Laminating
PSA tape lamination is the process of bonding two or more layers of material together to form a composite structure that combines the properties of each layer. This can involve the PSA layer itself, backing materials (such as fabric, film, or foam), release liners, and other functional layers. The process enhances the tape's characteristics, making it suitable for a wider range of applications. The specific method used can depend on the materials involved and the desired properties of the final product.
The benefits of PSA tape lamination include:
The ability to create short run hybrid tapes and materials
Adding capabilities to materials
Increased durability
Multi-layered materials
Added protection against moisture, vapor, etc.
Custom Fabrication from Our Adhesive Tape Experts
At Engineered Materials, we work with OEMs and other businesses to help them solve their most complex bonding challenges, From material selection to converting, we’ll create PSA tapes that give you the best bond performance and easiest application. How can you improve your bonding solution? Get in touch with our team to find out what’s possible.