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Compound Die Cutting Services of Electrical Insulators and Conductors for the Electronic Industry

Die Cutting of Electrical Insulators & Conductors
Die Cutting of Electrical Insulators & Conductors
Compound Die Cutting Services
Compound Die Cutting Services
Compound Die Cutting Services of Electrical Components
Compound Die Cutting Services of Electrical Components

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The electrical insulator shown above was developed in-house by our staff in conjunction with the client. The customer gave us their specifications for the insulator and upon ispection, their initial plan would require a costly manufacturing process. Working with them we developed a custom process that fully utilized our strengths, and allowed us to produce a product that not only met their requirements, but was much less expensive to manufacture.

The insulator is used to stop current flow thru a specific part while allowing the current to pass across the part. It is composed of three materials that are layered and die cut. The conducting layer is a copper foil with a pressure sensitive adhesive. The insulating layers were composed of a 0.005" thick mylar polyester film and a 0.010" thick black polycarbonate. The insulator was formed using a blanking compound die, with matching male and female components. During the stamping process the material passes through the die set, stopping while the die closes and stamps the shape. The stamped part falls through the bolster plate into a container for collection and laminating.

Quality control is maintained through 5 piece inspection on all dimensions for pre-production samples, and first and last piece inspection on production runs. In addition, constant visual monitoring is performed during the production run to verify proper lamination (no de-laminating at edges especially). To date we have produced over 3 million of these items, with three week lead times.

For more information on this project, see the table below or contact us directly.

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Highlights of this Compound Die Cutting Project

Product Description Electrical Insulator
Compound Die Cutting Capabilities Applied/Processes Primary:
Stamping
Laminating
Equipment Used to Manufacture Part Compound Blanking Die
Overall Part Dimensions Length Overall: 2.245"
Width Overall: 1.920"
Thickness: 0.018" (total, all 3 components and PSA)
Tightest Tolerances +/- 0.005"
Material Used Copper Foil with Pressure Sensitive Adhesive (PSA)
0.005" Mylar Polyester Film with PSA
0.010" Black Polycarbonate
Material Finish Matte Black
In process testing/inspection performed 5 piece inspection on all dimensions for preproduction samples. First and last piece inspection on each production run. Constant visual monitoring during production run for proper lamination (no de-laminating at edges especially).
Industry for Use Electronic Industry
Volume Over one million parts produced.
Delivery/Turnaround Time Normal 3 week delivery on production runs. 6 weeks for samples because of tooling lead time.
Delivery Location Illinois
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Electrical Insulator and Conductor

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