What Materials Can Be Die Cut?

Die cutting can process almost any flexible or semi-rigid material that comes in sheet, roll, or laminate form — including foam, rubber, plastic film, adhesive-backed materials, paper and paperboard, fabric, cork, felt, and thin metal. The right material depends on your part's thickness, tolerance requirements, and whether you're running a prototype or full production volume. As a family-owned die-cutting shop in Queen Creek, AZ, we work across all of the material families below.

Below is a breakdown of the material families we cut most often, their typical thickness ranges, and which die-cutting process fits best.

Foam

Foam is one of the most common die-cut materials because it compresses easily and cuts cleanly with steel rule dies.

• Types: Polyethylene (PE), polyurethane (PU), EVA, neoprene, silicone sponge

• Typical thickness range: 1/16" to 2"

• Best process: Steel rule dies for most gauges; laser cutting for tight tolerances or intricate profiles on thin foam

• Common applications: Gaskets, packaging inserts, cushioning, weatherstripping

See examples of foam parts we've cut in our portfolio.

Rubber

Solid and sponge rubber die-cut well and hold tight tolerances for sealing applications.

• Types: Neoprene, EPDM, silicone, nitrile, natural rubber

• Typical thickness range: 0.020" to 0.500"

• Best process: Steel rule or rotary die cutting depending on volume

• Common applications: Gaskets, seals, EMI/RFI shielding backers, vibration dampeners

Rubber gasket cutting is one of our core services, from custom dies through full production runs.

Plastics and Films

Rigid and flexible plastics can be die cut, though brittle plastics may need a different die style to avoid cracking.

• Types: Polycarbonate, PVC, polyester (Mylar), acrylic, polypropylene, HDPE

• Typical thickness range: 0.002" to 0.250"

• Best process: Rotary die cutting for thin films at high speed; laser or CNC for thicker rigid sheet

• Common applications: Display overlays, membrane switches, packaging windows, protective films

Browse photos of finished plastic and acrylic parts in our gallery.

Adhesive-Backed and Laminate Materials

Pressure-sensitive adhesives (PSAs) and multi-layer laminates are a specialty of die cutting because the process can cut through bonded layers without delaminating them.

• Types: Single- and double-sided tapes, foam tapes, transfer adhesives, VHB

• Typical thickness range: 0.001" to 0.250" (including carrier and liner)

• Best process: Rotary die cutting, kiss cutting for liner-backed parts

• Common applications: Mounting tape, splicing tape, component assembly, electronics bonding

Hear from engineers and manufacturers we've partnered with on our testimonials page.

Paper, Paperboard, and Corrugated

• Types: Cardstock, chipboard, corrugated board, kraft paper

• Typical thickness range: 0.010" to 0.250"

• Best process: Steel rule dies

• Common applications: Packaging, point-of-sale displays, inserts, gaskets for light-duty seals
  

Fabric, Felt, and Cork

• Types: Non-woven fabric, wool and synthetic felt, natural and rubberized cork

• Typical thickness range: 1/32" to 1/2"

• Best process: Steel rule dies; laser cutting for clean edges on loose-weave fabric

• Common applications: Filters, acoustic padding, furniture pads, gaskets
  

Thin Metal and Metal Laminates

Die cutting isn't limited to soft materials — thin metal foils and metal-backed laminates can also be cut, typically with specialized tooling.

• Types: Aluminum foil, copper foil, brass shim stock, metal-backed EMI shielding

• Typical thickness range: 0.001" to 0.020"

• Best process: Steel rule or rotary dies with hardened tooling

• Common applications: EMI/RFI shielding, electrical contacts, thermal management components
  

Material Comparison at a Glance

How to Choose the Right Material for Your Part

Material selection usually comes down to three questions:

1. What does the part need to do? Seal against moisture, absorb vibration, insulate electrically, or simply hold a shape?

2. What's your production volume? Rotary die cutting is cost-effective at high volumes; steel rule dies are typically faster and cheaper to tool for prototypes and shorter runs.

3. What are your tolerance requirements? Tighter tolerances (especially on thin films and foils) often push the process toward laser cutting rather than mechanical dies.

If you're not sure which material fits your application, sending us your drawing or a sample of the environment the part will operate in (temperature, chemical exposure, compression) is the fastest way to get an accurate recommendation.

Frequently Asked Questions

Can die cutting handle multi-layer laminates? Yes. Die cutting is well suited to laminates — foam-to-adhesive, fabric-to-foam, metal-to-foam — because a single die stroke cuts through all bonded layers cleanly in one pass.

Is there a minimum or maximum thickness for die cutting? Most die-cut materials fall between 0.001" and 2", though the exact limit depends on the process. Steel rule dies generally handle thicker materials than rotary dies, while laser cutting favors thinner, more precise work.

Can die cutting achieve tight tolerances? Yes, particularly with rotary and laser die cutting. Steel rule dies typically hold tolerances around ±0.005", while laser cutting can achieve tighter tolerances on thin materials.

What materials can't be die cut? Very rigid or brittle materials — thick solid metal, glass, or ceramics — generally aren't good candidates for die cutting and are better suited to CNC machining or waterjet cutting.

Do you provide material recommendations if I'm not sure what to use? Yes — our engineering team reviews drawings and application requirements at no cost and can recommend a material and process based on your part's function, environment, and volume.

For more guides like this one, visit our blog.

Have a project in mind? Send us your drawing for a free engineering review and we'll recommend the right material and process for your application.

Contact

Reach out to discuss your die-cutting needs.

Email

Phone

engineering@southwestdiecutting.com

360-805-0100

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