Learn About CGR Products Laminating Services

At CGR Products, we laminate many different materials on a daily basis.  We can laminate materials up to 84″ wide and as thin as .062″.  Materials can range from closed cell foam to heavy fabrics.  In this series, we will look at some common ways CGR Products offers laminating services.

Heat Platen Laminating

This type lamination involves a process where the adhesive roll rides over a heated platen.  Heat is used to soften the adhesive which is typically called “Flow”.   The heat of the platen is computer controlled and is critical to the speed of the process.   The material being laminated is pulled through the machine via driven rollers and the adhesive is applied to the bottom side of the substrate.  The bond of adhesive to the substrate is performed at the nip roller.  Once bonded the materials can be rewound and supplied on a core.

Watch our video below of closed cell foam being laminated with 3M9495 double coated adhesive.

Infrared Laminating

Infrared laminating is similar to heat platen laminating other than the heat source.  This process uses Infrared heat to help the adhesive flow before it is applied to the material.  One benefit of infrared is the heat can be micro adjusted while in process which allows the operator to quickly find the optimum temperature to create the best bond.  The infrared process is instant so the heat can be started and stopped within seconds saving valuable time and material.

Camouflage fabric laminated to closed cell sponge rubber

Hot Roll Laminating

Hot Roll lamination involves applying adhesive over a heated drum.  The heated drum helps the adhesive flow just before being applied to the substrate. CGR Products hot roll laminator will handle materials up to 84″ wide.  Our hot roll laminator is well suited for materials such as carpet and textiles.  A common use for this machine is the process of glue web lamination.  This process allows customers to reactivate the adhesive with heat when parts are ready to be installed.

Rotary Laminating

For high volume die cutting applications, we utilize Rotary lamination.  We commonly laminate materials up to 16″ wide such as 3M VHB, Copper foils, and Mylar.   Depending on the complexity of the part,  we can usually laminate and cut the part in one pass.  This helps to reduce cost and increase responsiveness to your customer.

Learn More

To learn more about our lamination capabilities, visit our laminating services page.   Feel free to click around our website or visit our Sample Gallery to view a portfolio encompassing many of the industries we serve.

Gap Fillers for Acoustical and Ingress Protection

Elastomeric gap fillers come in many shapes and sizes,  from open cell foam used for acoustical management, to closed cell sponge used for sealing outside elements. In this article, we will discuss three types of gap fillers that CGR Products manufactures on a daily basis.

Open Cell Polyurethane

Open cell polyurethane is a great low cost material as a gap filler when sealing out water is not applicable.  Open cell foam is made up of cells that are intentionally left open, which results in foam that is softer and more flexible.  Its composition allows air and moisture to pass through so that when condensation takes place, the foam dries and doesn’t hold the moisture.

Open cell polyurethane works well for items such as bulldozers, excavators, generators, and other heavy equipment that have engines that generate a significant amount of noise.  Polyurethane foam gap fillers can help reduce engine noise and other acoustical noises when water ingress is not an issue.

Open cell polyurethane from CGR Products is available with or without adhesive on one side.  This material can be die cut into any shape used for a specific area or supplied in roll form.  Thickness typically ranges from .125″ to 1.25″.  We utilize an acrylic adhesive on our polyurethane foam for optimal long-term, durable applications.

Closed Cell Foam

Closed cell foam is made of cells that are fully closed and packed tightly together. This results in foam that is more rigid and stable than open cell foam.  Closed cell foam can block air movement and water ingress.  Due to the cell composition, closed cell foam is typically much denser than open cell foam.

Closed cell foam rubber can fill large voids and gaps, and also has cushioning properties to help lessen impact between two substrates. Closed cell foam is perfect for sealing gaps and helps reduce ingress, whereas open cell foam offers more flexibility.  Additionally, closed cell foam is ideal for outdoor applications because it resists weathering, UV rays, and fungi.

At CGR Products, we offer a variety of adhesive options for closed cell foam gap fillers. From economical “aid in assembly” applications to higher performance permanent bonding applications.  We can die cut these fillers into individual parts or they can be supplied in continuous rolls.  We skive our thickness in house to accommodate our customers exact specifications.

Crushed Semi-Closed Cell Foam

Crushed semi-closed foam is great for filling uneven gaps and sealing out acoustics, dust, heat, and air.  Semi-closed cell foam is a soft, flexible foam. It has good UV resistance and good resistance to ozone and weathering, making it an ideal material for both indoor and outdoor use. This soft, compressible closed-cell foam, can fill various types of gaps, impede heat, water, sound, and vibration, offering a solution for various uneven types of gap filler applications.  Semi-closed cell materials combine the flexibility of open cell materials with the excellent sealing capabilities of closed cell foams.

As with our closed cell foams, CGR Products offer a variety of adhesive options for semi-closed cell foam gap fillers.  We offer die cutting, and various types of fabrication, such as layering and bonding different types of foams.  An example of a layered gap filler is a closed cell foam on the bottom for rigidity and support, bonded with a crushed foam on the top for compression and uneven surfaces.  Crushed semi-closed cell gap fillers can be die cut to meet specific sizes or supplied in roll form.

Learn More

Consider CGR Products when you are developing gap fillers for sound and ingress protection.  With over 170,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the heavy equipment industry. To learn more about our capabilities visit our Die Cutting pages or visit our Open and Closed Cell Foam pages to view a portfolio of the different types of foam we work with.

Noise, Vibration, and Harshness (NVH): What You Need to Know

Guest Author: Technicon Acoustics

Noise, Vibration, and Harshness (NVH) is a concern for many companies.  One of our long time suppliers Technicon Acoustics has provided the below resource and also has a full version pdf available to download here.

The extraneous sound and vibration are more than just an annoyance for people who work around noisy machinery. Excess equipment noise creates a perception of low quality that can decrease the perceived value of an OEM’s product. Noise and vibration are first and foremost bothersome, but it can also cause underlying issues of increased wear and tear, ultimately leading to shorter equipment life. These results have detrimental effects on the marketability of the product, decreasing its appeal to the customer. 

Fortunately, there are methods to decrease excessive noise and vibration to optimize performance and enhance the overall consensus of your product. 

What is the Meaning of NVH? 

NVH stands for “Noise, Vibration, and Harshness.” NVH seeks to understand the source of industrial noise and modify equipment to reduce it. When looking for methods to diminish the noise and vibration from machinery, Technicon Acoustics relies on these core principles when engaging in equipment modification:  

• Reducing the source strength 
• Interrupting the path of the noise and vibration 
• Absorbing the noise and vibration 
• Smoothing out sound quality and annoying tones 
• Increasing speech intelligibility inside of the machinery 

Sound waves move outward from their source at different strengths and speeds, depending upon the mediums they encounter. Installing the right kind of barrier material deflects sound waves, reducing their impact. Some mediums absorb sound waves rather than allowing them to proliferate. Specialized foams are often used to absorb sound waves caused by vibrations.  

The field of NVH has its roots in the automotive industry. Sound dampening methods were originally developed to reduce the noise produced by automobiles, but now noise and vibration control techniques are applied across an array of industries. 

Engines and motors on machines and vehicles are the primary sources of noise in an industrial setting. Interrupting the path of the noise involves installing barriers within the machinery, as well as equipping individual components that are prone to vibration with damping material that reduces vibrations. By addressing both structure-borne and airborne noise the overall sound quality of the machinery improves. In turn, this improves the ability of operators or passengers to understand one another or to hear the speech from a GPS or radio. This is the definition of speech intelligibility. 

Increasing Sound Quality and Speech Intelligibility 

Not all sound is created equal. The different sounds and their harshness all have a unique perception to the individual. Some noises may sound alike, but have certain attributes which make it more disturbing. A tone is defined as any frequency bin that has a dB rating of +/- 3dB from the previous bin, which makes the difference audible and annoying to the human ear. There are methods to reduce noise and vibration, but masking the harshness of the noise needs to be accounted for as well. 

By properly addressing the noise sources, the acoustic signature becomes less harsh. No one wants to be in or around a piece of equipment that has a loud annoying tone to it – whining, thumping, scraping, etc. Improving the sound quality of a machine and smoothing out the annoying tones helps improve speech intelligibility, which is vital inside cabs or simply being around the equipment. 

In an ever-growing world of digital communication, speech intelligibility is not just important for person–to–person interaction. Devices also need to be able to understand voice commands that are given by the operators and vice versa.  

Why is Measuring NVH Important? 

Measuring NVH and implementing the correct acoustic solutions will enhance the value of your product. Customers commonly look for the equipment and machinery that check all the boxes on their shortlist, which always includes a product with the least amount of excessive noise, vibration, and harshness.  

With vehicles, noise originates in the powertrain, which includes the motor, engine, exhaust, and all ancillary support systems. At lower speeds, powertrain noise is the most noticeable type of sound. At higher speeds—those exceeding 100 km per hour—rolling noise takes over. Rolling noise is directly tied to airflow. An everyday example of this would be to compare the noise generated by a car in city traffic compared with the noise generated on the highway.  

Vibration is caused by the sound waves generated by moving components within the equipment or vehicle. As sound waves emanate from their source, they reverberate off of other components and cause them to vibrate as well.  

When it comes to perceptible sound, the human ear has a wide range. We are able to sense anywhere between 20-20,000 Hz. It is critical for engineers and manufacturers to reduce the upper threshold of their equipment’s NVH sources during the design process to appropriately mitigate risks posed by industrial noise.  

Lowering NVH Levels with Technicon Acoustics 

When dealing with sources of NVH, there are two types of sounds that need to be considered:  

• Structure-borne 
• Airborne 

Structure-borne sound results from all moving components within the machinery. Airborne sound is generated by the equipment’s aerodynamics and combustion processes and is transmitted directly to your ear. Together, these two types of sound compose the machinery’s overall acoustics.   

Technicon Acoustics uses different solutions to reduce harmful noise. Designed to address the three core NVH principles, these solutions include: 

• Acoustic absorbers 
• Acoustic barriers 
• Damping materials 

Acoustic absorbers are made using porous materials like polyester foam and polyester fiber. These absorbers are installed on sound-reflective surfaces to prevent airborne noise from proliferating and affecting equipment operators and bystanders.  

Acoustic barriers are made from mass–loaded vinyl, a dense material that stops sound waves from spreading. Barriers serve as an environmental modification and are often installed on surfaces surrounding industrial machinery or in the cab of a vehicle.  

Certain materials actually amplify the frequency and harshness of sound waves. Damping materials such as PVC and foam composites dissipate sound waves before they amplify and are used to keep the interiors of large-scale mass transit vehicles comfortable for passengers.   

Click here to download the full NVH materials guide PDF.

CGR Products has worked with Technicon foams for well over 30 years, providing solutions ranging from small gap fillers to full enclosure panels.  As flexible material specialists, the CGR Products team offers years of experience in converting foam materials into gaskets and components. Our in-house precision cutting services include rotary, flatbed,  kiss cutting, slitting, waterjet, knife cutting, and more.

Speaker Gaskets for OEM Manufacturers

CGR Products works with many manufacturers die cutting speaker gaskets.  Our gaskets are used in several markets including, marine speakers, automotive speakers, home speakers, and more.  Our die cutting capabilities allow us to cut virtually any size and pattern for large volume applications.  This article will describe a variety or materials and cutting methods used to produce speaker gaskets.

Materials

CGR Products stocks several raw materials used for speaker gaskets.  Materials such as closed cell sponge, cross linked polyethylene, and urethane foam are commonly used.  Closed cell sponge is the most common material used by speaker manufacturers. In the case of rear mounted speakers, a material such as closed cell sponge, or cross linked polyethylene (XLPE) is highly desired to make an airtight seal.  Later in the speakers life, if rear mounted, the speaker can easily be removed with no damage to the enclosure.

For conventional speaker mounting, the gasket is used to make a seal to a mounting ring, or to give the speaker better esthetics.  Material such as closed cell foam or urethane foams is typical for these applications.

Die cut gaskets from the above-mentioned materials allow for an easy installation.  CGR Products die cuts gasketsfrom all of these materials plain, or with adhesive. Materials laminated with adhesive on one side provide an easy installation by the OEM.  The gaskets will have a removable liner on the mating side, allowing for a quick peel and stick application.

CGR Products die cuts dampening or batting material for all types of speaker enclosures.  Typically, this material is either a non woven polyester batting or 2lb open cell urethane foam.  Depending on the cabinet design, we will die cut panels for the whole cabinet, or critical pads that are mounted strategically for dampening.  The dampening is critical in automotive applications to keep rattles and vibrations to a minimum.  These materials can also be laminated with adhesive if desired.  With polyester batting, CGR can add a heat activated glue web.  Urethane foam can have adhesive with a removable liner for peel and stick application.

Die Cut Gasket

CGR Products can die-cut products up to 75″ wide x 84″ long in a single stroke. For segmented parts, we can incorporate “dovetailed” or interlocking parts.  For supplying high volumes of speaker gaskets, this method of die cutting is the most desired for cost savings.  CGR Products will design the stamping tool to allow for the best material savings plus maximize throughput to reduce cost.  Cutting high volumes of parts are what we do best and set us apart from our competitors. Our large format cutting operation has its own dedicated shipping dock with 7 bays.

CGR Products also uses a variety of waterjet machines for cutting speaker gaskets.  Waterjet cutting offers excellent material yield and the ability to cut a multitude of materials. The CGR waterjets require no tooling or tool maintenance, lowering your initial set up charge.  We use custom made waterjet machines with multiple cutting heads to allow for multiple cuts at the same time.

Knife cutting is another exceptional option for fabrication tasks that require precision cutting without the use of waterjet machinery. Our state-of-the-art knife cutting machinery utilizes a serrated (dentated or toothed) blade in the Z-axis. This ensures the production of a precise end product, every time, no matter how intricate the details. The machine is powered by advanced control software and a powerful, versatile cutting head.  CGR’s knife cutting machine eliminates the need for cutting dies and increases yields to enable quick turnaround and higher precision.

Learn More

CGR Products is capable of producing custom speaker gaskets for a variety of applications.  With over 170,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the speaker industry.  To learn more about how CGR Products can help with your die cut speaker gaskets, Contact Us today. Ready to get started,  Request a Quote for your die cut parts.

Why does my dog look me in the eye?

Why does my dog look me in the eye?  He could look at my ears, my nose, my shoulders, etc.; but for whatever reason he looks into my eyes.  And why does he cock his head a bit sideways when he is focused on trying to understand what I am saying?  And finally, why I am spending so much time thinking about these types of things?

First, I am thinking about weird and different stuff because of COVID.  I am noticing things I have never noticed before and that is one of the very good things that has come out of these challenging times.  I think my dog and all animals know to look into our eyes because they know that eyes are the key to connection and communication.  I think my dog cocks his head sideways because he is trying as hard as he can to listen and understand me.  We can learn a lot from these behaviors.

Eye Contact

I have had about a million virtual meetings, just like everyone else, and the one thing I really dislike about them is that no one looks anybody in the eyes. I can look at the camera, so everyone thinks I am looking in their eyes, but then I do not get to see other people’s eyes.  If I look at the other participants eyes, they do not get to look into my eyes.  Technology has come a long way, but they still have not invented a camera that can follow your eyes. I guess that is why I got so focused on my dog’s eyes and the pleasure I have gotten from our eye contact. As you know roughly 60% of human communication is through body language, 30% is through voice intonation, and only 10% is through what is actually said. It would not be hard to argue that the most important part of body language is your eyes. That is what you are mostly looking at in any person to person interaction (or person to animal).  You know how I know when I have done something wrong? You got it, my wife’s eyes.  Frankly, I can tell way more from her eyes than what she says.  All animals use body language to assess their surroundings; trust, fear, and comfort to name a few.  Since eyes are the most important “tell”, that is why dogs look at your eyes.

Listening

Listening to actual words has also taken on a new meaning during COVID.  I need to cock my head sideways more because it is harder to read body language on the computer screen and even noticing intonation can be hard in this virtual world.  I must listen to the words more to tune out the dogs, kids, and interesting visuals that come along with virtual meetings.

Staying Focused

Another thing I have learned is how productive I can be working away from the office; you are not interrupted so you can stay focused, you have more usable time due to no car time or ad hoc discussions, etc. Before COVID I would check emails and may have done some busy work when I was not in the office, but I did not do a lot of real heavy brain work like I do now. I have also noticed how mentally exhausting it is when I work off site. So why is that?  I think it is because when you work off site, you get very few breaks, so you have many straight hours of intense brain activity. That is very tiring to this old boy. So, most people would say that more productivity is the way to go so why not work off site all the time. Seems easy right?

As with all things there are two sides to the story. Being mentally tired every day is not great for my marriage and not being in the office is not good for collaboration or culture building. Out of the one million virtual meetings I have had, I have not had one that has produced as many new ideas and free flowing collaboration as my normal in person collaborations.  I am going to suggest that is because people need full communication, body language, intonation, and voice to be the most effective when collaborating. That total communication, and especially eye contact, are critical when building culture.  It creates trust, energy, and connection like the dog assessing his surroundings.

My point is that there are real positives to working off site and there are real positives to in person collaboration.  It is going to be important for all of us to strike that proper balance to take advantage of both benefits.  I am guessing that there will be some combination of off-site work and in person collaboration.  I think we will land at some set times in the office for everyone and the rest is up to the individual.

New Things Learned

This has been a historic time and I am really proud of the CGR team.  Our business fell off a cliff in April.  We implemented new safety protocols, reviewed numerous financial models, and overhauled our business operations.  As the year wraps up, I can honestly say we have exceeded my expectations.  We have grown, persevered, and laughed a lot, in lieu of crying.  I will be happy to see COVID go, but I will look back and be thankful for the numerous new things I have learned and contemplated because of it.

CGR really appreciates our connection to our associates, customers, and suppliers and I personally appreciate everyone that decided to read this and experience my attempt at being a psychologist. Have a great holiday season and for what it is worth, I really love my dog!

Heat Sealed 3M™ Thinsulate™

CGR Products has been supplying various types of 3M™ Thinsulate™ materials to the automotive market for more than 10 years.  The 3M™ Thinsulate™ NVH material (noise, vibration, and harshness) is used in a variety of applications across many different industries and provides a wide variety of sound absorption and dampening properties.

The Advantages of 3M™ Thinsulate™

3M™ Thinsulate™ NVH Material provides a reliable acoustic solution for various automotive applications.  3M™ Thinsulate™ is engineered to provide high-performance sound absorption.  Specific products are engineered to assist in the creation of lower profile products and reduce mass in the automobile while also reducing noise around the vehicle.  3M™ Thinsulate™ is water repellent to absorb minimal moisture; thus, no need for an additional waterproof layer. It is also resistant to mildew growth, eliminating the risk of unintended odors.

Heat Sealing Thinsulate™

CGR Products supplies custom cut 3M™ Thinsulate™ to the automotive industry utilizing a heat seal around the perimeter of the part.  Some of the benefits of a heat seal include:

• Preventing contaminants into the part.  If your part is located in an area prone to dust, dirt or any other foreign contaminants, a heat seal is an ideal way to keep much of the substance out of the part.
• CGR can supply custom cut Thinsulate™ in a variety of ways, such as individual parts stacked in a box, or perforated on a roll.  If a heat seal is used, the parts will retain their shape and remain stable dimensionally.
• Visually Appealing. If you have a die cut part that is visible, you may be interested in a heat sealed edge. This type of edge will provide a more finished look as opposed to an open, fibrous part.

Keep in mind that for most die cut Thinsulate™ parts, the heat seal is not needed.  However, if there are OEM requirements or if you are looking at exterior parts, a sealed part may be what you are looking for.

Learn More

Consider CGR Products when you are developing sound and vibration dampening.  With over 140,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the automotive industry. To learn more about our capabilities within this field, download our automotive application guide, or visit our Sample Gallery to view a portfolio encompassing all the industries we serve.

CGR Products is Helping To Fight COVID-19

Just a few months ago, we would have never imagined we would be fighting the pandemic that we’re now facing.  CGR Products is currently classified as an “essential business”.  We die cut critical engineered parts that go to other essential businesses.  The amount of inquires we’ve received has been both overwhelming and a blessing, including companies that range from major automotive manufactures making ventilators to high school students 3d printing face shields in their homes.

The president of CGR Products recently gave an interview with our local news affiliate regarding how we are helping fight COVID-19 which you can find Here

Helping in the Fight

A few products that went into production extremely fast are gaskets used for ventilator timers, die cut face masks, and die cut foam strips used on face shields.

Ventilators

The ventilator gaskets are a specialized neoprene rubber that have a 3M high temperature adhesive on both sides.  We used to cut these gaskets years ago but the company moved the production overseas.  Within 10 days we were able to locate the tooling which we still had, ordered the specialized material, and started die cutting the parts.  The parts were then rushed to a major USA based automotive manufacturer where the ventilator is being produced.

Face Masks

A local company reached out to us about die cutting their own material to make face masks in a rush.  This customer brought us a prototype of the mask and the material to be used. The face mask design is a closed cell material that is washable and reusable. From the sample, we created the tooling in house and started die cutting the masks.  We were able to create a die to maximize the customers’ material utilization and start cutting immediately.

Face Shields

Face shield foam strips have also been in huge demand.  We have been supplying these strips in materials that range from open cell polyurethane foam, to closed cell sponge.  With closed cell sponge, CGR Products can split these materials to any specific thickness.  We have seen thickness requests that range from .500″ to 1.25″ for these strips.  We then apply adhesive to one side of the materials and either die cut to the finished desired strip or supply the materials in roll form.

A student from an area high school reached out to us looking for a material to use on face shields.  The school has 3D Printing as part of their curriculum and they started making the clear plastic portion of the face shield.  Here at CGR Products, we stock a wide variety of closed cell sponge and offered the school Armacell 3091 to use as the foam strip.  We supplied them strips die cut 1.00” thick x 1.50” wide.  The completed face shields were then supplied to medical staff in the local hospitals.  Attached is a link from Armacell, regarding materials used for face shields.  Foams for face shields.

We Are Ready to Help

CGR serves a diverse range of clients, including those in the medical equipment industry.  To learn more about how CGR Products can help with your die cut parts, please Contact Us today. Ready to get started,  Request a Quote for your die cut parts.

Large Format Die Cutting

CGR Products has actively been die cutting high volume parts for more than 40 years. To accommodate either very large die cut parts, or supplying parts in a prolific fashion, we use a process called “Large Format Die Cutting”

Equipment

CGR Products utilizes two Bruno die-cutting presses. Bruno presses are made in the USA and used by large manufacturing companies throughout the world, primarily in the automotive and gasket industries. These presses cut against a flexible conveyor belt to move raw material and the die cut parts along in an automated fashion.

Both presses use steel rule dies as the cutting method. CGR Products creates and maintains all our steel rule dies in house. These dies are typically made with heavy gauge and long length steel rule to accommodate thicker materials. These presses can hold a die up to 84″ x 75″ or roughly 7ft x 6ft.

Process

The process is similar to what is found in most die cutting operations but on a much larger scale. Raw Materials in Roll form or Sheet form are fed into the front side of the presses. Most flexible materials such as rubber, foam, and Thinsulate can be fed in multiple layers providing more throughput per cycle.

The raw material advances under the cutting platen via the conveyor belt. With the die attached to the top of the platen, a “stroke” is made. The steel rule die cuts through the raw material down to the conveyor belt. Once cut, the material advances out on the conveyor belt and a new cycle will start again. The die cut parts at the back end of the machine will be taken off the conveyor belt and packaged.

Advantages

For us at CGR Products, we are primarily cutting flexible materials and typically utilize these machines in two different ways.

• To cut very large parts that no other machine can convert.
• To cut very high volumes of parts that no other machine can convert efficiently.

To expand on large parts, let’s consider the insulation for a vehicle door panel. The non-woven raw material comes in rolls and wide widths. Typically the die can be nested so the entire vehicle door panels can be cut in one single stroke. If the material can be layered, then you can greatly increase your throughput. These die cut insulation panels can then be stacked in returnable containers that go directly to the OEM.

For high volume parts, the process will be more complex. The number of die cavities can be immense and the throughput can be monumental. For example, we die cut millions of foam filtration parts. With a standard die cutting press we could get 12 cavities on a single die. With our Bruno die we have 264 cavities. That is a difference of 252 parts per stroke and with simple math, the throughput numbers to keep up with demand add up easily. It takes CGR Products years of experience running large cavity dies while maintaining high quality, to maintain these stupendous volumes.

Cutting high volumes of parts are what we do best and set us apart from our competitors. Our large format cutting operation has its own dedicated shipping dock with 7 bays. This allows for truckload quantity operations of unloading one set of trucks while filling another set of trucks. CGR Products has the ability to work with our customer’s computerized interfaces and portals, allowing order to flow directly to our large format cutting department.

Find out More.

With over 170,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the automotive industry.  To learn more about how CGR Products can help with your large volume die cut parts, please Contact Us today. Ready to get started,  Request a Quote for your die cut parts.

If You Want to Influence People, Pay Close Attention to Emotions!

I have a technical behavior type and I pride myself on making fact-based decisions. As my years in the work force have progressed and my hair has moved past grey to white, I have come to realize that emotions are way more important than facts when working with others. For a person like me to say that is groundbreaking. Over the years my wonderful wife Merrill and I have had a few disagreements, okay maybe more than a few. When those altercations happen, it has become a standing comment from her to say, “I couldn’t care less about the facts, let me tell you how this makes me feel. At that point in time, I realize two things; first, I better change the way I am approaching the topic, and second, that I have probably lost this round. You see in my world, I cannot possibly understand how facts don’t rule the day in any decision, but in my wife’s world, and in many people’s world, emotions play a major part in how decisions are made.

A Powerful Example

To prove my point let me explain the strangest situation I have encountered. Most people think that facts should and do rule the day in our judicial process, or at least that is what we think should happen. Our company was sued along with 20-25 other companies. It was clear to me that our company should not be involved. I was deposed by numerous lawyers, some in person and some on the phone over the course of a day. In the mediation that followed all the companies met in some building in some city.  We were all sequestered in separate rooms with our lawyers while the mediator went from room to room to try to get as many companies to settle out of court as possible. When the mediator came to our room, my attorney explained that we had submitted documentation and that we should be dropped from the lawsuit. After one minute the mediator left and went back to the plaintiff’s lawyers to try to understand the situation. Shortly after that, the plaintiff’s lawyer came to our room. For those of you who have been in a mediation, that is not how this works. The plaintiff’s lawyer spent the next 15-20 minutes clearly outlining my defense. I was shell shocked.  They clearly knew we had no business being there. So, I’m thinking what the heck is going on and why was I there?  During the day long deposition, they felt like I was the type of witness that would connect well with the “emotions of a jury”.

Then she said that she wanted me to testify in front of a jury because my testimony would help them against the other defendants.  In return, if I would agree to testify, they would ultimately let us out of the lawsuit. Again, shell shocked.  After some private time with my attorney, I decided that I was not up to all that, so we settled for a nominal amount and I went on my way.  That single event solidified to me just how important emotions are even in a scenario where I thought facts would or should rule the day.

Winning People Over

Recently, I finished the book, “Never Split the Difference” by Chris Voss.  He was the chief hostage negotiator for the United States for 13 years.  This is an excellent book and I would highly recommend it.  For me, it challenged and erased much of what I have learned about negotiating, or a better way to say that is about how to “win people over”.  This book focused almost entirely around the importance of emotions in getting what you want in any situation.  That leads me to my point.  If you want to be successful, spend the necessary time to understand people’s emotions.  The only way to do that is to listen to people and to understand what their body language is telling you.  People will not work effectively with you if they think you don’t care about them.  Genuinely caring for someone or feeling cared for by someone is totally emotional.  You can do your best to try and verbally convince someone that you care for them by saying whatever facts you would like; how much time you spend with them, how you helped them on a project, or how you get them coffee periodically, but unless they feel genuine caring, you are wasting your breath.  They are going to feel what they are going to feel, and it is your responsibility to figure that out.

Have you ever had a decision to make and the facts clearly tell you what you should do, but for some reason, it doesn’t “feel” right?  This is an example that we have all had, so if you don’t think emotions dictate your decisions, think again.  Most people call that their intuition.  Why do people spend too much on a car, a house, or in my wife’s case clothes (I hope my wife doesn’t read this)!  Emotions matter.  Realizing that will make you more successful.

For more than 50 years, CGR Products has been a leading supplier of reliable, high-quality products.  To read more from CGR Products, visit our Blogs page or feel free to click around on our website.

Making Things A Little Easier – Using Pull Tabs and Split Liners

Sometimes removing the liner from a die cut part can be difficult and when it comes to high volume applications, saving time can add up to dollars in the bank.  One way of achieving a simple time saver is adding a pull tab or split liner to the die cut part used during assembly.  In this blog, we will highlight a few of the ways CGR Products achieves these added benefits.

Pull Tabs

A pull tab in its simplest form is an area of the adhesive release liner that is kiss cut adjacent to the part to allow for easy liner removal.  Kiss cutting is a process where the die cuts through the part but stops short of cutting through the liner.  The greatest benefit of pull tabs is ease of liner removal during assembly.  A pull tab creates a better grip and allows for faster and more consistent processes.

I will explain this using the photo to the right as a reference and how it is used.  This particular fastener is 3M™ VHB™ tape used to hold a mud flap on a vehicle.

• This material comes in master rolls and has the factory red 3M™ film liner on one side (left)
• We laminate the 2nd brown Kraft liner to the backside of the 3M™ VHB™ tape  (right)
• During the die cutting process, the part is cut all the way through both liners and the tape around the exterior dimension.  The tab at the top of the part is created by kiss cutting to the red liner and removing the VHB tape, thus creating the “tab”.
• The die cut VHB™ parts with the pull tabs as shown are then shipped to the manufacturer making the plastic mud flap, typically a tier supplier.  The tier supplier will remove the brown Kraft liner and apply the VHB™ part to the mud flap. The Kraft liner is a heavy board stock and removes easily by hand. Once applied these assemblies are shipped to the automotive OEM.
• During assembly at the OEM, the associate (or robot) simply grabs the pull tab and removes the film liner which exposes the adhesive, then adheres the mud flap to the automobile body.

Sometimes depending on the material, the excess material of the pull tab does not need to be removed.  A material such as closed cell sponge will allow the sponge to stay on the tab, giving the user even more area to grab.  In this case with VHB™ tape, the excess material has to be removed because the adhesive can fuse back together.

As shown in the example above, the pull tab is basically external to the VHB™ part. The pull tab is created by removing the extra material.  This extra material is wasted and factors into the part cost to some degree.  A rather easy analysis can be made between the added costs of the pull tab versus the cost of a standard die cut part, along with the associated cost of labor to remove the liner.

Sometimes when designs allow,  pull tabs can be internal.  Internal pull tabs will be used where scrap is already present thus not adding to the material cost.  The example below will show this best.  This gasket is a typical id/od rectangle.  The center will be scrapped regardless.  This pull tab is kiss cut down to the red liner and the pull tab is exposed when the waste is removed.

Tabbing Tape Pull Tab

When gasket designs or lower volumes prohibit a pull tab from being created, an alternate method known as “tabbing tape” may be used.  Tabbing tape is typically a specialized adhesive film that is supplied in rolls.  The roll will consist of small rectangles of a special adhesive that will stick to a silicone treated liner.  There will also be a “dry edge” portion of the tab where no adhesive is present to allow for the grab point.  The tab is placed on the die cut part liner, then using a heat bond gun, the tab is bonded to the liner using heat and pressure.

When done properly, the tab will make a permanent bond to the liner.  Many factors have to be considered when using tabbing tape such as liner type, accurate placement, surface cleaning or buffing, temperature, pressure and dwell time.

Analyzing the differences

Adding a pull tab to a die cut part will take into account several factors, such as volumes, shape, layout, material selection, thickness, and adhesive types.  Understanding these factors will determine if a pull tab can be external, internal or none at all.   An external pull tab will typically be preferred due to the ease of use.

Die cut parts with pull tabs can commonly be produced on high volume runs where extra costs can be absorbed.    Typically the cost of adding a pull tab increases the cost of the die cut part due to extra processes or run times during manufacturing.  Depending on volume, these costs versus a standard die cut can be proportionate.  These extra manufacturing processes are also why it is not feasible to add pull tabs on low volume parts.  Set up times and run rates for low volume parts would inflate the price substantially.

Split Liners

Split liners are another way to save time and money during assembly.  Split liners come into play when very high volumes are being processed.  A commonly seen example of split liners is the liner used on most band aids.

Processing split liners involves precision die cutting machinery and high precision tolerance rotary dies.  Typically the adhesive is applied to the material first, and then at the die cutting stages, the part and split liner are cut in sequence.  The dies used in this die cutting stage are machined to very high precision allowing just the liner to be cut alone.

The costs in tooling are typically more expensive than standard steel rule dies; however, being used in high volume applications the cost is absorbed over the life of the program.  The tooling is a one-time cost, and a quality high precision tool will cut for several years afterward.

Just as when analyzing a pull tab, a rather easy analysis can be made between the cost of the split liner, versus the cost of a standard die cut part along with the associated cost of labor to remove the liner.  In the case of end user applications such as band aids, it becomes a matter of ease of use for the individual.

Learn More

Consider CGR Products when you are developing your next high volume die cut parts.  With over 170,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients, including those in the automotive industry. To learn more about our capabilities, visit our High Volume Rotary Die Cutting Page or feel free to Contact Us today.