5 things to know about Die Cutting
More cutting methods are available now than ever before. In the early days, Friction Sawing used to be the “go-to” material cutting option. Now, there are literally dozens of choices. In this blog, we’re going to focus on Die Cutting and determine if it’s right for you.
What is Die Cutting?
According to Wikipedia, Die Cutting is “the general process of using a die to shear webs of low-strength materials, such as rubber, fiber, foil, cloth, paper, corrugated fiberboard, paperboard, plastics, pressure-sensitive adhesive taps, foam and sheet metal”. Die cutting provides versatility in fabrication and allows us to make custom parts, like gaskets across a variety of applications and are perfect for providing high volume precision cutting.
1.) Benefits of Flatbed Die Cutting
First, there’s Rotary Die Cutting and Flatbed die cutting. Flatbed Die Cutting is the process of cutting or perforating the desired shape our of material using a hydraulic press. Flatbed cutting reduces overall cost and used generally for large production runs, higher cutting efficiency, high part consistency. The Flatbed cutting process allows quick change over times from one part to another which increases overall efficiency.
2.) Common Applications
- Acoustical Insulation
- Heavy Equipment
- Medical Equipment
- Power Tools
- Truck Body and Cab
To see the industries we serve, click here: //www.techniconacoustics.com/industries/
3.) Die Cutting is perfect for custom kits
Die Cutting allows customed engineered designs to be cut into one large piece with perforated cuts, with each individual part separately labeled. This allows for quicker receiving and an overall simplified inventory process. Kitting makes assembly workers more efficient and increases output helping you reduce labor costs.
Worried about Quality and re-work? At Technicon, for the previous 12 months, our quality performance was 99.98%. See the //www.techniconacoustics.com/company-about-us/the-perfect-order/
4.) Puts the “Lean” in Lean Manufacturing
Die Cutting reduces Material wastes and costs, time set up, loss and decreases parts. The more parts the less the efficiency.
- Saves on Storage Space
- Just In time delivery- get what you need exactly when you need it
- Get custom packaging
5.) Die Cut Gaskets
Are reliable, customizable, and cost-effective. Die cut gaskets can be produced on rotary or flatbed equipment that helps reduce overall cost. At Technicon, we have a multiple point checklist in the production process. Pre- Production Planning or (PPP) can cut costs to make sure that everything is examined and in order from the time of the RFQ to purchasing and packaging. Die cutting allows us to give you design flexibility, low set up cost and supply chain flexibility.
When you’re not really sure what solution you’re looking for you usually search for “soundproofing”. We receive calls that sound like “how do you make this oxygen air compressor quiet?” Or Is there a way to soundproof my office?
People are convinced that soundproofing foam, sound absorbing foam or soundproofing panels are the “cure all”. Well, doesn’t foam stop sound? No. Foam doesn’t “stop” sound. It absorbs echo. This is a common misconception that follows confusion when OEM’s and everyday people are looking for sound solutions for their next project. Let us help you understand the difference and which one is best for your next project.
What is an Absorber?
First, let’s determine what an Absorber does. Sound absorbers are porous materials used to line hard sound-reflective surfaces to reduce airborne noise. Airborne noise is a sound that is transmitted through the air, typically generated by
- Television and Radio
- Animal Sounds
In construction, you typically find structure-borne noise which is transmitted through a solid structure, such as steel, wood, concrete stone etc. Once the sound strikes the material, the sound energy is dissipated as heat. Typical absorbers used are acoustical foams and fibers. At Technicon Acoustics we produce absorbers that are acoustical foams and fibers for both functional and aesthetic purposes with a wide variety of foam or non-woven absorbing materials. Common examples of sound absorbers are open cell foam and polyester fibers. To determine the amount of material necessary to reduce the noise, our engineering team uses our Acoustics Lab to ensure there are no gaps, cracks or leaks to allow sound to escape from the enclosure.
Common Uses of Sound Absorbers
• Machine enclosures
• Generator, air compressor, & water pump enclosures
• Engine compartments
• Truck & heavy equipment cabs
• Home appliances
• Medical equipment
What is a Barrier?
Barriers (soundwall, noise wall) are slightly different than absorbers because they are used to block noise transmitting from one location to another. A Sound Barrier is a Mass Loaded Vinyl (MLV) used to reduce the amount of airborne sound transmitting through a wall,
floors, ceilings etc.
While Barriers are heavy as lead, they usually aren’t that thick. This allows the MLV to improve Sound Transmission Loss without taking up space; like at a Construction Site. Barriers can be wrapped or be used with other material like our Thermal Solution Product Tech Shield.
Common Uses for Sound Barriers
• Machine enclosures
• Engine compartments
• Cab floors
• Pipe Wrap
Protect Components from Damaging Heat
Technicon Acoustics TECH SHIELD ™ TS-040 is designed to shield components from radiant heat sources. Made from a flexible and lightweight inorganic core that is naturally flame retardant and thermally insulating, our new TECH SHIELD ™ offers a noticeable drop in “cold side” or “body side” temperatures allowing for improved comfort inside cabins and operator environments. The high performance PSA offers quick and easy installation to a wide variety of surfaces.
Tech Shield is ideal for applications in Heavy Equipment, Specialty Vehicles, Power Generation, Appliances, Heavy Truck, and Automotive Industries.
- Firewall & Underbody
- Exhust & Turbo Trouble Areas
- Hose & Tubing Protection
- HVAC Thermal Protection
- Fuel Tank Shielding
Benefits during the initial design
There are new methods and processes that are constantly changing the game for designers. Partially the reasoning for this problem is the ever-growing challenges designers face every day.
Development Speed: Constant Revision and parts not being efficient or poor quality
Complexity Management: If the project is overly complex, usability and budget can be difficult. This increases risk and chances of error.
Customer Involvement: Keeping potential customers involved is tricky. Questions are needed to get the appropriate feedback that will help move the project forward.
Sustainability: You can have a killer design idea, but either the products aren’t sustainable on either an economic or environmental level. Costs are too high for large quantity production not to mention recyclable or minimizing the use of materials ensures good global citizenship.
So first, keeping all the challenges in mind how do you not only address key product design issues, but design to reduce noise and more importantly manage cost? Well, let’s look at the benefits of providing a Sound Solutioned Environment.
An environment that provides reduced noise levels increases efficiency and improves output and can minimize hearing loss claims. In a classroom, It can increase learning capabilities and clear speech. According to the United States General Accounting Office “21,900 schools exhibit poor acoustics or noise control, affecting over 11 million students. 28.1% of all schools reported unsatisfactory or very unsatisfactory environmental noise conditions. This was higher than ventilation (27.1%), physical security (24.2%), indoor air quality (19.2%), heating (18.9%), or lighting (15.6%)” Reducing noise in the workplace can have health benefits by reducing Cardiovascular Disease and Workplace distractions.Global Analytics writes ” Businesses lose about $600 Billion Dollars a year in workplace distractions” You get the picture. Basically, NOT designing for noise can be expensive. So let’s look at the different types of noise, how to discover acoustical mistakes BEFORE they are made, and important key design elements to consider.
Air Borne or Structure Borne
What is Airborne Noise? Airborne Noise is a condition when sound waves are being carried by the atmosphere. Examples are Engine Noise, Turbo Whine, and Fan Noise…Structure-borne Noise is Mechanical Vibration in a structure which can become an audible sound. Example: Mounted Devices, Sheet Metal Structures, and Body Panels.
Airborne noise can be reduced through proper design elements and acoustical treatments. The primary consideration in design to reduce airborne noise is to make sure that all air paths, in or out of the enclosure are tortuous. This eliminates the line of sight noise transmission. Another design consideration is to ensure that all doors and access panels are properly fitted and gasketed to provide a complete seal. As little as 10% untreated surface areas will reduce the effectiveness of acoustical treatments by up to 50%. All interior surfaces of the enclosure should be treated using the proper acoustical absorber or absorber/barrier composite.
Structure-borne noise can be reduced by considering the nature of the structure-borne sound which can vary significantly depending on the source of the vibration, the composition of the structure through which it will transmit. The radiating surface and the character of the receiving space.
Key Design Issues
When looking at using the right products you should know that there is no such thing as one right material for all applications. For example, Barrier composites only need to be used between noise sources and OCCUPIED areas. Absorber products are less expensive, lighter and will make a major impact that will fill gaps and voids. More is not always better. If there is more than 5% untreated area, don’t waste money by adding mass. Something that happens quite often is the absorber is often covered. Covering the Absorber negates its purpose. There are other ways to get the look you want like with different facing combinations so it’s important to consider the environment and know the frequency. All acoustic products have a signature. We can help you pick the right one for your application
Key Take Away’s
- Treat as close to the source as possible
- Block the Noise Paths
- Leave room for treatment
- Use the right products
Treat at the source, Block the path, and Plan for materials
Treat at the source
- When you treat close to the source of the noise; if can you treat smaller areas and you eliminate secondary effects. For example, soft engine mounts to isolation engine vibration and stop structure-borne noise. Soft mount gensets, inverters, and other equipment. Use sound shields/enclosures around equipment where possible.
Block the noise paths.
- Structure Borne noise will travel along all rigid hard connections until it finds a sympathetic surface to radiate sound. To solve this problem, you can introduce isolation barriers where practical. Airborne noise will follow all air paths and reflect off all hard surfaces. Here, you can make sure all air paths are either sealed or “tortuous”. You can line as much surface area as possible with sound absorbers or absorber/barrier composites.
Plan for Acoustic Materials
- Be sure to leave space for treatment. Minimize equipment attached directly to bulkhead adjacent to occupied areas by either stand-off the attachments or attempt to make attachments on the outboard or other non-occupied bulkheads. Be sure to leave room between hulls, bulkheads and other structures for the application of sound absorbers and composites. We would typically recommend a 3″ recommended clearance.
There’s is no such thing as 1 material for all applications.
– Barrier composites only need to be used between noise sources and OCCUPIED areas. You can also use absorber product because it’s cheaper and lighter and will make a major impact in reducing noise if you fill all the gaps and voids.
More is not always better.
-Too much over-engineering has been done in the past. If there is more than 5% untreated area, don’t waste money adding mass.
Keep these rules in mind:
1.) Don’t cover the absorber
- Covering the absorber negates its purpose. There are other ways to get the look you want.
2.) Find the right mounts
- Many equipment manufacturers do not do the work required to provide the best vibration isolation mounts.
3.) Consider the environment
- If the product will be exposed to heat, water, diesel, gas, etc make sure it’s going to stand up.
4.) Know the frequency
All acoustic products have a signature. Pick the right