Advantages of Rotary Die Cutting

Rotary die cutting is a quick, cost-efficient way to manufacture products that require precise shapes, cuts, and folds without sacrificing speed of construction. This makes it a great way to build mass-produced items like boxes and other packaging from paper, plastic, and metal, as well as electronic component assembly parts, decals, stickers, foam products, and more.

Although other die cutting methods exist (such as flatbed, matched metal, and laser die cutting), rotary die cutting is often the best choice for industrial uses. It is quicker than both flatbed and laser die cutting and it can easily manage heavy or tough materials.

HOW ROTARY DIE CUTTING CAN STREAMLINE YOUR PRODUCTION PROCESS

Although all types of die cutting bring their own benefits—and in some cases, you might use more than one method for the same die cutting project—a rotary die cutter offers several advantages that place it above other methods:

  • Ease of cutting: Rotary die cutting machines can cut through just about any material, from paper and magnets to foam, metal, and cork, at efficient speeds.
  • Speed and efficiency: Rotary die cutting is an excellent choice for completing large production runs. Since the cutting pattern is set in the machine, it does not need to be adjusted between cuts, meaning that it can process large amounts of material with little to no error.
  • Quick turnarounds: Rotary die cutting’s efficiency makes it easy to move materials from concept to finished product.
  • Precision: Rotary die cutting replicates precise cuts, so you can be sure each item you produce is identical to the last. It’s the most accurate die cutting option, which is why it’s often favored for production runs that require consistency and uniformity.
  • Less waste: Rotary die cutting creates less waste than other procedures, which is both more economical for the company and more sustainable for the environment.
  • Multipurpose: Rotary die cutters can perform several tasks depending on the project’s needs, such as laminating, kiss cutting (to create adhesives), embossing, and more. They can also perform inline packaging as required.
  • Durability: Rotary die cutting machines rely on straightforward processes that result in minimal wear and tear on components.

CUSTOM DIE-CUT PARTS FOR ANY APPLICATION

Because rotary die cutting is so effective for creating metal products, it’s commonly used to build electronic parts. Due to their conductivity and malleability, metals like copper, nickel, aluminum, and silver are regularly used for electronic components like capacitors and transducers. These metals are all easily cut with rotary die cutting.

But that’s not all: many other industries use rotary die cutting to quickly, efficiently, and accurately produce all sorts of small products. Some of the most prevalent manufacturing sectors that use rotary die cutting include:

  • Shipping: Shippers use rotary die cutting to manufacture cardboard boxes, envelopes, tickets, stickers, labels, and more
  • Medical devices: Rotary die cutting consistently delivers the precision and detail required to create a wide array of medical parts
  • Aerospace and automotive: The method is regularly used to create heat shields and sensitive navigation components
  • Appliances: Rotary die cutters work with a wide range of materials to  create sound-dampening foam products for use in appliances

EXPERT ASSISTANCE FROM OUR DIE-CUTTING EXPERTS

Whether you face tight deadlines, need precise replication, or require high-volume production runs, using rotary die cutting brings many advantages to help satisfy your demands. The custom die cutter team at Robert McKeown Company, Inc., is happy to work with you to create the custom or standard parts that your needs.

From simple systems to complex components, we’re up for all types of assignments and look forward to working on yours. Request your quote for your project to learn more about what our team can do for you.

The Versatility of Liquid Silicone Rubber

Liquid silicone rubber (LSR) is a two-part, platinum-cured elastomer that manufacturers inject into mold cavities to create components that withstand weather extremes and product aging. This versatile product remains useful in temperatures as low as -65°C and as high as 150°C.

LASTING BENEFITS FOR ANY APPLICATION AND INDUSTRY

Several additional characteristics render LSR the material of choice for many different applications and industries. Some key examples include:

  • Biocompatibility: LSR’s elastomeric composition enables it to resist bacterial growth. It’s entirely tasteless and odorless, and tests have indicated exceptional compatibility with human body fluids and tissue
  • Chemical resistance: LSR can resist oxidation and corrosive chemicals
  • Temperature resistance: LSR can withstand low and high temperature extremes
  • Mechanical properties: LSR offers high tear resistance and tensile strength along with excellent flexibility and elongation capacities
  • Electric properties: LSR can insulate against many different forms of electricity
  • Transparency and pigmentation: Because LSR is naturally transparent, it allows manufacturers to create colorful and fully customized rubber-molded products

CONSUMER GOODS AND ELECTRONICS

Consumers today seek high-quality, durable goods built to last. Working LSR into your manufacturing processes can make the difference between products people buy and products they leave on the shelf. LSR silicone appears in a diverse field of everyday items such as:

  • Kitchen goods: Baking pans, spatulas, barbecue brushes, and cooking pans
  • Cosmetic goods: Mascara brushes, makeup applicators, and lipstick molds
  • Wearable technology: Fitness trackers and smartwatches
  • Electronics: Small components like connector seals, grommets, and strain-relief devices

AUTOMOTIVE INDUSTRY

LSR is seeing an exponential rise in use among vehicle manufacturers. Because it can withstand extreme weather conditions and stretching, it’s an excellent material to use in a variety of automotive applications, including:

  • Windshield wipers, which incorporate LSR due to its heat resistance and flexibility
  • LED headlights, which use LSR’s transparency to amplify emitted light, resulting in better visual clarity for drivers; because LED bulbs use less energy than other light bulbs, LSR enables cars to be more energy efficient and budget friendly
  • Airbag coating and sealing
  • Components used under the hoods of vehicles
  • Buttons, gaskets, and wiring harness components

HEALTHCARE AND MEDICAL DEVICES

LSR helps manufacturers create safe and reliable medical devices and components. Medical devices need to operate within tight tolerances to improve the safety and health of patients and providers. LSR helps meet these specifications while keeping parts cost efficient:

  • Medical devices placed inside patients’ bodies are commonly made of LSR, because this material won’t leak potentially dangerous chemicals
  • Drug-eluding devices (DEDs)
  • Flow-control valves and syringe stoppers
  • Baby care products
  • Implants
  • Wearable devices for monitoring
  • Respiratory masks

BUILDING LSR SOLUTIONS WITH ROBERT MCKEOWN

LSR brings widespread benefits to a diverse array of industries, and our team will work with you to create products that you can distribute with pride. If you would like to learn more about how our LSR products will improve your latest project, contact us and request a free quote today.

Versatility of Liquid Silicone Rubber

EMI Market Trends and Solutions

Electromagnetic interference (EMI) — also called radiofrequency interference (RFI) when occurring in the radiofrequency spectrum — refers to an electromagnetic disturbance caused by an electronic device interacting with another electronic device. Electromagnetic induction, electrostatic coupling, and conduction can all disrupt the electrical circuit of the affected device. EMI can cause major problems for a huge range of applications, and is becoming a greater concern in today’s increasingly connected world.

EMI Market Trends and SolutionsEver wonder why wireless devices must be put on airplane mode or turned off during a flight? Electromagnetic waves emitted when using those devices can actually interfere with the plane’s navigation system.

As the use of technology and electronic devices continues to rise, the EMI shielding market is rapidly expanding. Government guidelines outlining EMI shielding requirements are also expected to shift. And as technology use increases, electronic devices are becoming smaller and smaller, and the use of Wi-Fi, GPS, and Bluetooth is becoming more and more common. Both of these trends — the miniaturization of devices and the increased use of wireless technologies — can contribute to EMI problems.

EMI SHIELDING MATERIALS

EMI shielding is extremely important in today’s ever-shifting landscape, and we’re proud to partner with Parker Chomerics, a leader in EMI shielding innovations offering a range of different of products including:

EMI SHIELDING GASKETS

EMI shielding gaskets from Parker Chomerics can eliminate all types of EMI gaps. Common applications include EMI window seals, grounding tabs, server face plates, panel seals, cover seals, and door seals.

EMI SHIELDED WINDOW

These windows not only guard against EMI, they also protect displays from scratches and breakage, and can withstand harsh conditions. EMI shielded windows can be used with the above-mentioned EMI shielding gaskets, as well. Common applications include electronics used in military and medical environments, instrument panels, and cabinets and racks.

METAL FOIL TAPES

Parker Chomerics offers a few different types of shielding tapes, available in aluminum, copper, tinned copper, nickel-plated, and, if appearance is a concern, embossed types. These tapes are perfect for EMI cable shielding, especially when dealing with surfaces that cannot be soldered.

EMI SHIELDING PAINTS

Paints are ideal for scenarios in which common EMI shielding products will not work, such as high-altitude environments. You would not want to wrap EMI shielding tape around an airplane, for example. Parker Chomerics offers a range of different paints to suit specific shielding applications, such as circuit boards, plastic enclosures, electrolytic platable plastic, aircraft airframes, and aluminum and composite.

ELECTRICALLY CONDUCTIVE ADHESIVE

Various types of adhesive are available from Parker Chomerics, all designed for use in applications requiring sturdy, conductive electrical bonds. Adhesives are often used to fill cracks in electrical boxes, poor-tolerance enclosures, and EMI vents and windows.

ELECTRICALLY CONDUCTIVE SEALANTS

Sealants are important for filling in gaps on electrical enclosures or electrical grounding. This is often required for man-portable electronics, military ground vehicles, and radar and communication systems.

EMI SOLUTIONS FROM ROBERT MCKEOWN CO.

Since 1937, Robert McGeown Co., Inc. has been providing clients across diverse industries with world-class engineered materials for the electronics industry. Specializing in application assistance for both new and existing product design, we can offer high-performance, tailored solutions for all types of shielding needs thanks to our state-of-the-art proto-fast design center. We also keep a bulk inventory, allowing us to provide customized materials even for low-volume orders.

To learn more about Parker Chomerics’ industry-leading EMI shielding solutions and discuss options for your unique application, request a quote today.

EMI Market Trends and Shielding Solutions

Dow Corning® EA-7100 For Electronic & Automotive Applications

Dow Corning® has demonstrated time after time its endearing qualities as a global leader in adhesive silicone adhesive technology and products; the company has done it again with the introduction of its new Dow Corning® EA-7100 Thermal Radical Cure (TRC) Adhesive. With its 2015 nominations for the prestigious R&D 100 Award in both the Market Disrupter category and the Mechanical Devices/Materials category, Dow’s new TRC adhesive promises to offer “game-changing benefits” to its customers in the transportation electronics sector.

Car abstract concept

Among the potential applications for this breakthrough in adhesive technology are the assembly of electronics housings, the attachment of connectors, electronic control units (ECUs), lighting and display modules, or sensors, to an unprecedented variety of substrates.

A BREAKTHROUGH IN ADHESION AND CURE TIME

The list of materials that EA-7100 has demonstrated compatibility with include metals such as aluminum, brass, copper, and steel, as well as ceramics, glass, laminates, silicones and plastics that typically haven’t had good cohesive adhesion properties. Compatibility is possible with polymer plastics such as polycarbonates and polyethylenes (including LDPE and PEX), Nylon, acetal plastics, Plexiglass®, PVC, liquid crystal polymers, and cured silicones; often without pretreatment or specialized cleaning. Dow indicates that it expects this list to continue to grow as new applications are developed and tested, and there is no doubt that robust adhesion to such a diverse range of materials will enable new product designs that may revolutionize the manufacturing of automotive electronics.

The unique ability to bond to so many substrates magnifies the overall performance of TRC adhesives when presented with their low voiding and significantly reduced cure time compared to conventional heat-cure, platinum catalyzed silicone adhesive systems. The adhesive has demonstrated the ability to achieve a full cure in as little as 15 minutes at 100°C compared to the longer 60 minute cure time of conventional single-part, addition-cure adhesives at 125°C. In some applications, cohesive adhesion begins in as little as 3 minutes, a quality that, along with lower cure temperatures, is sure to increase production efficiency in the manufacture of transportation and automotive electronics products. This highly effective curing process yields lower energy use and lower material processing costs.

A NEW KIND OF CURE

With the onset of cohesive adhesion occurring in as little as 3 minutes, Dow Corning’s EA-7100 can cure to a wide range of substrates simultaneously. Curing and adhesion begin before skin-over, in bulk, and at the bond line, and 100% adhesion is achieved immediately after cure time. While the adhesive surface exposed to oxygen remains tacky until its dual cure system is completed, the cohesive adhesion allows for immediate hot testing, and surface tack can be reduced by curing the adhesive in a low oxygen oven.

Typical “addition cure” silicone adhesives have shown sensitivity to certain contaminants such as amines or sulfur, that interfere with bonding, but EA-7100 has proven to be unaffected by either. As a thixotropic adhesive with reduced viscosity under agitation, it requires neither extensive cleaning before application nor pre-treatment in most cases. With little to no cleaning or pre-treatment required, primers, plasma, and UV or corona processes can be reduced and possibly eliminated in some applications, another cost reducing benefit.

ENHANCED ADHESIVE PERFORMANCE

What does it take for a high-performance silicone adhesive to claim the title “high performance?” It’s more than just versatility among a variety of applications and substrates, lower cure temperatures, and less cure time; it also requires enhanced adhesive properties. Properties such as adhesion, shear, tensile strength, resistance to corrosion, and superior reliability under water immersion and salt water spray environments make Dow Corning EA-7100 stand out as a high-performance adhesive.

EA-7100 shows adhesion strength up to 350 PSI to aluminum substrates, while adhesion to PBT thermoplastics such as Ticona® and BASF® is even higher; up to 380 PSI at 100% cure. With a Shore A durometer hardness of 43, it’s tensile strength is a whopping 490 PSI, and its shear strength on aluminum and PBT substrates is over 350 PSI (after only 30 minutes of cure time).

GREATER DESIGN FLEXIBILITY AND COST CONTROL

Dow Corning EA-7100 Adhesive was developed to give manufacturers of automotive electronics and electronics modules greater design flexibility and cost control. This innovative one-part thixotropic adhesive technology widens the possibility for new, improved models with more superior performance potential and more cost control than previously available for applications in automotive and transportation electronics.

Durable adhesion to a wide range of substrates is formed simultaneously with the cure, increasing the flexibility of new product designs. Both faster cure times and lower cure temperatures increase production efficiency and reduce energy costs. Small void formation, reduced sensitivity to contaminants, and improved adhesion in harsh environments including hot and cold temperature extremes, salt spray exposure, as well as both fresh and saltwater immersion also enhances new design possibilities.

MORE APPLICATION POSSIBILITIES

The opportunities for applications in the manufacturing of transportation and automotive electronics are as diverse as can be expected for a Dow Corning adhesive product. EA-7100 can be considered for a variety of uses in the assembly of plastic and metal electronics housings and components, as well as for attaching electrical connectors, lighting components, and sensors to a wide range of substrates.

Possibilities for powertrain applications in the electronic management of engine performance and emissions, control of automatic gearboxes, and in the management of power steering and braking functions include various ICU modules and sensors that can benefit from this new adhesive technology. Safety and driver assistance sensors and controls such as those used with airbags, crash detection, tire pressure monitoring, adaptive lighting, and speed control functions would also benefit from this innovative adhesive technology. There are numerous applications in driver and occupant comfort, climate control, power accessories, and power distribution as well. Contact the Robert McKeown Company at solutions@robertmckeown.com or 800.631.1125 to discuss your application with one of our in house engineers.

About Dow Corning

Dow Corning is a global leader in innovation of adhesive, sealant, and silicone technologies that include more than 7000 individual products and services. With more than 25,000 corporate customers worldwide, Dow Corning offers innovative products and solutions for a diverse range of industries, manufacturing, and service sectors.

Experience the Product’s Performance First-Hand

For a sample of EA-7100, or to learn more call the Robert McKeown Company at 800.631.1125 or email solutions@robertmckeown.com

Henkel Adhesives Deliver for Wearable Electronics

From smart watches to user interface glasses, wearable electronics are on the edge of technology allowing consumers to take their smart gadgets on the go. As the demand for mobility rises, devices get smaller and the technology to manufacture them continues to advance and evolve. The rigorous demands of wearable electronics are keeping adhesive technology at the forefront of innovation.

Henkel Adhesives Deliver for Wearable Electronics

HENKEL ADHESIVES PROVIDE HIGH-PERFORMANCE SOLUTIONS

Wearable electronics demand requires performance and reliability under the most adverse conditions. Exposure to shock, stress, vibration, extreme temperatures, and water/moisture can’t be allowed to affect performance and reliability. In this rapidly growing market where less is more, there is no place for bulky adhesive products on devices where size and limitations are crucial. Manufacturers of wearable technology depend on Henkel for the adhesive solutions they need to take their complex products from the design table to the production line.
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Robert McKeown Co. Hosts TECHNOMELT™ Workshop

Join us Tuesday, June 28, 2016 at 10 a.m. for a TECHNOMELT™ Low Pressure Molding Adhesive & Technology Workshop featuring LPMS USA and Henkel Electronics.

Technomelt WorkshopAt the workshop, you’ll learn how to cut costs, improve manufacturing efficiency and offer a one-step molding alternative to your customers.

Michael Pierce Henkel will speak on their full line of TECHNOMELT™ materials with focus on the new thermally conductive TC 50 and PA 668 materials. Rob Michael will review the key innovations of their line of low pressure molding equipment and will provide demos with the Beta 600 as well.

The TECHNOMELT™ family of low pressure molding solutions address demanding protection against solvents, moisture and chemicals, high temperatures and adhesion to multiple types of substrates. Henkel’s TECHNOMELT™ materials are fast, simple, and efficient with each molding operation enduring a short cycle time (30-60 seconds) at low pressure.
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Custom Services For High Tech Electronics Assembly

Robert McKeown Company, Inc. prides itself on providing a myriad of custom assistance services and products such as:

We Specialize in Short-Run and Quick Turn-Around!

X-Y Parts Cutter, Clicker Steel Rule Die Cutting, Rotary Die Cutting of custom and standard Electronic Component Assembly Parts, Epoxy Film Adhesives, Gaskets, Thermal Interface Adhesive Parts, EMI/ESD Shields, Dupont™ Kapton® Solder Masking Dots, Conformal Coating Masking Dots, Powder Coating & Painting Masking Dots as well as Pressure Sensitive adhesive backing for Industrial, Electronics, Aerospace, Mechanical, Mil-Aero and Flat Plastic Parts applications.

X.Y. Laser Converting

The X.Y. laser converting system is one of the top systems available. The continuous and automatic device increases as it goes, removing parts from the sheet with almost no material limitations. This system can increase productivity, with defect-free and tool-free cutting. X.Y. laser converting can also eradicate layout limitations and reduce scrap material costs all while reloading jobs in no time and providing a consistent cut-to-print registration.

X.Y. Laser Converting
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Loctite Ablestik SSP 2020

LOCTITE introduces ABLESTIK SSP 2020. An Ag-based material that delivers a robust intermetallic bond between targeted surfaces, the substrate and die, via a pressureless or pressure sintering process. This solution, ideal for high power devices, facilitates much higher thermal and electrical conductivity than traditional die attach adhesives and has performance equivalent or better than solder — all while meeting the stringent requirements of lead-free legislation. The technical staff at the Robert McKeown Company is available to assist you with integration of SSP 2020 into your manufacturing process.

LOCTITE ABLESTIK SSP 2020
is a sintering silver paste die attach adhesive designed for devices requiring elevated thermal and electrical conductivity capabilities. It is formulated to provide high heat transfer generated from power devices. It maintains high adhesion at operating temperatures as high as 260°C. It is stencil printable and syringe dispensable.

  • Ideal for high power devices
  • Delivers a robust intermetallic bond between targeted surfaces
  • Facilitates much higher thermal and electrical conductivity than traditional die attach adhesives
  • Provides strong adhesion
  • Compatible with current production equipment, high throughput
  • 10x thermal cycle & power cycle performance better than solder

Loctite Ablestik SSP 2020
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Henkel Loctite GC10

Henkel Loctite GC10 is the industry’s first temperature stable solder paste. GC10 is stable at 26.5 degrees Celsius for one year and at temperatures of up to 40 degrees Celsius for one month. This temperature stability provides tremendous benefits throughout the logistics and operations chain.

Click here to download a PDF copy of the Henkel Loctite Game Changer 10 Specifications

In production, Henkel Loctite GC10 offers huge improvements over conventional solder pastes in printed circuit board assembly. As compared to traditional materials which average abandon times from 1 to 4 hours, this halogen-free, lead-free, temperature-stable formula enables abandon time of up to 24 hours and has a startup time of zero. Stabilized and consistent print transfer efficiency, an expanded reflow window and increased activity for better results with soak temperatures between 150 degrees C and 200 degrees C, make Henkel Loctite GC10 incomparable among solder pastes. And, GC10’s dependability on the line yields material utilization of over 95%.

Henkel Loctite GC10
By using Henkel Loctite GC10 the Robert McKeown Company offers its customers both process improvements and cost reductions. The temperature stability of this product will eliminate the challenges with shipping and storage. GC10 is setting a new standard for high performance solder materials with improvements in production, higher yields and ultimately better profitability.

For a sample of Henkel Loctite GC10 or to speak with a technical specialist call 800.631.1125 or email sales@robertmckeown.com
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