Category Archive: Uncategorized

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.

 

 

 

Component Foams Specifically Engineered for Automakers

Guest Author: Isabell Wright, Armacell LLC.

For most major car makers, all parts must be made from materials that are on their approved source list. It’s a competitive business and only the best suppliers with a proven track record of quality, new technology, on-time delivery and service will make the cut. Once a material has been included on the approved source list or our fabricator partners have been selected as preferred suppliers, the task is not over. We must continually maintain or improve our specs to stay competitive and meet the high expectations of auto makers and their supply chain.

Armacell’s foam is used in automotive components such as gaskets for sealing out water, air, dust or noise.

FIAT CHRYSLER AUTOMOBILES

In the 1930’s Chrysler was known for its iconic Chrysler building in New York City and affordable luxury vehicles. Now they are known as a maker of family cars including a hybrid. Armacell makes a number of materials on the approved source list for FCA including Monarch 3091® and EnsoLite® EF0 which meet the MSAY 430 spec. Both have the necessary resistance to UV, weathering and acid. They meet the horizontal burn requirements for interior automotive gaskets. EnsoLite EF0 has the added benefit of being a super soft and conformable, semi-closed cell, crushed foam that works well in applications that require the material to spring back to its original thickness.

Armacell made more than 6 million square feet of EnsoLite SF0 in 2018

 

TOYOTA MOTOR CORP

For 75 years, Toyota has disrupted the market and revolutionized manufacturing. As a maker of cars that are known for efficiency and reliability, Toyota stands by their brand. It makes sense that they insist on suppliers that do the same. Armacell makes a number of products that meet the tough Toyota TSM 1501G spec for automobile parts. Monarch 8002 is a 100% EPDM bun that has a dependable resistance to corrosive acids, UV and weathering. That means the material will hold up to the abuse auto parts take over time. EnsoLite IG1, manufactured in continuous rolls or sheets, has excellent resistance to oil, fuel and flame. These qualities make EnsoLite and Monarch great choices for gaskets and seals in automotive design.

 

Click Here to Download the Full Automotive Component Foams PDF.

To learn more about Armacell Products, visit their website – Armacell LLC.    For your next foam project, click Here to use the online Armacell Product Selector.

As flexible material specialists, the CGR Products team offers years of experience in converting foam material into gaskets and components. Our in-house precision cutting services include rotary and flatbed die cutting, kiss cutting, slitting, splitting, knife cutting, and more.

 

Benefits of Using a Vendor Managed Inventory (VMI) System

Vendor Managed Inventory (VMI) can be an effective strategy for companies looking for cost savings and a more stable supply chain.  In this post, we will outline the benefits of VMI as well as the services that CGR Products provides with these programs.

What is VMI?

 

VMI is a program where the supplier manages your inventory for you.  These programs helped make some of the largest retailers the giants they are today.  After seeing these successes, manufacturing caught on as a way to move toward lean practices and to become a demand-driven supply chain.

Traditional method

With traditional purchasing and stocking methods, sales are predicted and inventory is ordered based on the forecast.  This method comes with risks of buying too much or too little.  In the event of too little inventory, a risk may be present if the supplier cannot meet the higher than expected demand and lost sales may occur.  Too much inventory will tie up money and can cause warehousing (cashflow) issues.

VMI method

With VMI, the goal is for the customer to only buy what they are moving.  Using VMI requires a very close relationship between the customer and the supplier.  Using technology to maintain constant contact between both parties, the customer can purchase in smaller batches and avoid emergency orders.  Using this data allows both parties to work off of much more accurate forecasts.

 

CGR Products & VMI

CGR Products has been providing VMI services to our customers for many years.  Based on great relationships and communications with our customers, we keep properly maintained inventories based on actual usages and forecasts.   Our VMI programs give us more control so we can manage raw materials and be more efficient.

 

CGR Products can offer many different configurations of VMI.  Working with our customers to find the VMI system that works best for them is the key.

One common aspect of the program is a bin system that is serviced by our own delivery driver.  Highlights of this system are:

  • Bins are set up at the customers’ location where they are physically needed.
  • The driver counts the inventory on hand.
  • Determines the appropriate re-order quantity based on recent usage and predetermined stocking levels.
  • Enters the quantity consumed and the quantity to be re-ordered.
  • Electronically scans the provided barcode label on each bin to assure accurate capturing of the item details.
  • Orders are electronically transmitted directly into CGR’s manufacturing system via our proprietary inventory technology.
  • On the next visit, stock is rotated, new stock is scanned into inventory, and the bins are refilled to the acceptable level.
  • VMI runs on a revolving weekly schedule, with deliveries occurring once per week or multiple times per week depending on customer requirements.

Other Programs CGR Products currently works with include EDI and Portals.  CGR Products works directly within customer portals to maintain inventory and execute orders.  Orders are electronically placed directly into our manufacturing system from the portal.  These types of systems allow for more accurate order fulfillment with fewer errors and often include electronic shipping notices, invoicing, and payments.

Benefits

With an effective VMI system, the benefits are shared for both parties.  Some of these benefits include:

  • Ensuring the necessary parts are ready and available when needed.
  • Smaller orders allowing for lower inventory costs.
  • Better inventory turnover rate.
  • Reduced administrative costs.
  • More stable supply chain.
  • Close communications and partnerships between customers and suppliers.

Find out More.

To learn more about how CGR Products can help with your critical inventory management, please read our article on how OEM’s can optimizing their supply chain.

Ready to get started,  Contact Us today or look into taking advantage of our OEM Partner Program.

 

 

 

Running an Effective Meeting

Do you want your credibility to skyrocket? Learn how to run great meetings!

I was recently attending a social gathering and a gentleman that served on a committee where I was the chair over 10 plus years ago came up to me and introduced me to his wife as the guy who ran the best meetings he has ever participated in. He went on to tell her that he was quite sure that I ran a solid business simply because of the way I ran the committee meetings. It was a pretty funny and interesting interaction especially because I did not know him that well and I certainly did not and don’t know him well enough for him to know whether our business is solid or not. The point is that he drew that conclusion simply because of how I ran meetings.

Insights

With most jobs you go about your normal daily functions by yourself or with small informal interactions with your peers. Formally scheduled meetings are relatively infrequent and the ones you personally organize are even more infrequent. In any group setting regardless of whether it is work-related or not, the people involved are always forming opinions of everyone else. A meeting is no different. It is a human instinct when you are in a group setting to assess everyone else and form judgments of the other people. It comes from our survival instinct. People need to know if anyone in the group poses a threat to their safety.  Now, let’s consider a meeting scenario.  All participants will be analyzed by all the other participants.  It stands to reason that if you are the organizer of a meeting, you are probably going to be assessed at least as much as anyone else and probably more.  This gives you the chance to enhance your credibility, and in turn, you have the chance to hurt it.

The funny thing is that it is not hard to run an efficient, organized, and productive meeting. Let’s dig into some simple guidelines that, if followed, can make you look like an all-star.

Preparation

First, and by far, the most important part of any meeting happens before it even starts. From an importance standpoint, 75 percent of the success of a meeting depends on the pre-meeting preparation. Send an agenda well in advance of the meeting with the following information: the time, start and finish, the place, the invitees, the objective, all necessary information, and who is responsible for what. If there is any necessary information needed by any of the participants to prepare for the meeting, make sure they get it in plenty of time to fully digest it. Let everyone know they need to have read and understood all the pre-meeting information because you will not read it over in the meeting. I can’t stress this enough. So many people expect to be “babysat” if they are not the meeting organizer. Don’t let that happen, they have a responsibility to be prepared as a participant as well. I have seen too many meetings drag on because you must review information that should have been read and understood before the meeting ever started.

 

Stay on Time

Next comes the meeting. Always start on time. If anyone comes in late don’t backtrack to catch them up. It wastes everyone else’s time and they will realize that in the future they better be on time for your meetings. I have said before to a late participant that “their time must be more important than anyone else’s”.  I say it jokingly, but it definitely gets the point across.  At the start of the meeting outline the objective(s) of the meeting.  Then start through the agenda.  Make sure everyone participates and is given the opportunity to contribute.  That said, make sure you keep the meeting on task. We all know how much time can be wasted on topics that have nothing to do with the original objective(s).  It is critical to refocus the group if the meeting heads off course. If there are topics that come up that need to be addressed but are not part of this agenda, assign an action item to that topic to be addressed at another time. Occasionally, as the meeting organizer, you must use your judgment to decide how far to let a topic “wander”.  Sometimes straying a bit off topic can be very beneficial and allow the group to discover a new idea or concept. That judgment is the art of running a meeting, but be careful, that can quickly be the downfall of a meeting.

Finally, make sure you end the meeting on time. People’s schedules are tight, and they appreciate it when you get them out when you said you would. If there are topics that were not covered, schedule another meeting to complete those topics. When a meeting is set to end at a certain time, people subconsciously prepare themselves mentally for that time. If you go past, you lose them. At the end of a meeting always summarize the progress made toward the objective(s) and assign actions items to people including expected completion dates. Thank your team and adjourn.

After the Meeting

The final part of any meeting is the aftermath. Send out meeting notes that include the objective(s), any notes on progress toward the objective(s), and the assigned action items with a due date. These notes need to be sent in a timely manner after the completion of the meeting. I would suggest no more than 24 hours. Put tasks in your personal task list to follow up on the assigned action items on the due date if they have not been completed.  Doing this holds everyone accountable.

 

Running great meetings will increase your personal credibility and make the organization better.  Who knows, maybe one day someone will come up to you at a social gathering and introduce you to their wife or husband by telling them how well you run a meeting.  Good luck and I look forward to participating in your next meeting.

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.

Making a Decision

making a decisionOver my career, I have had the opportunity to experience many decisions being made, a nice way to say I’m getting old. I have seen good ones and bad ones and I have made good ones and bad ones. Ultimately, over 90% of the value any person is to any organization is directly related to their decision-making ability. Any decision is, at its core, a risk assessment.  You must assess two or more potential directions and then choose the best one.  There are always pros and cons to those directions.  Making a decision may seem easy enough, but there are many skills and factors that are part of that process.

 

Emotional Strength

There are several personal skills necessary for good decision making.  By far the most important quality and the one that is the hardest to find in people is having the emotional strength to do it. The biggest issue I have seen that holds most people back in their respective career is having the emotional strength to shoulder the responsibility for a decision as the risk increases.  In other words, as the emotional or financial risks increase many people shy away from making a decision. It is one thing to decide whether to go left or right at a stop sign, it is completely different to decide if a person is in the right job or if you should spend a million dollars with no guarantee of success and 100 people’s income is affected by that decision. So many people either don’t want that burden or the stress of that burden is too much for them to handle.

Understanding Data

Having the ability to understand all the information involved in a decision is another skill that is necessary to make good decisions.  Information comes in many forms. For example, there is empirical data, concepts, emotions, and situational considerations to name a few.  Typically, people have their strengths and weaknesses depending on the type of information that they are assessing.  I do not understand quantum physics and for me to understand it, I would have to spend so much time learning it that it would not be worthwhile. To put yourself in the best situation to make good decisions you should honestly assess yourself and seek input when you are dealing with information that is difficult for you.  One of the best businessmen I know has a tough time understanding the emotional impacts his decisions have on his team. He knows that about himself and does a tremendous job seeking input from other people that understand those impacts better than he does. From a big picture perspective directing your career so you are dealing with information that you know well helps you be a more effective decision maker.  However, no matter what career field you chose, you should always continue to learn and improve on your strengths and weaknesses, so you can make more effective decisions.

Filtering Data

Once you understand the information, you need to be able to filter the information.  If you struggle to filter what is important to the decision at hand, that information is useless. In almost every scenario, regardless of how risky the decision, there are 2 or 3 main factors that will determine the outcome of that decision. Too many times people are overwhelmed with the amount of data they must synthesize.  You must be able to identify the most important factors and eliminate everything else.  The inability to weed out all the noise will paralyze a person’s ability to decide.

Timeframes

Another criterion for effective decision making is being able to decide in a productive time frame. If it takes you 5 years to make a decision, you will not make many of them over your lifetime. There is an efficient period to make any decision. The riskier the decision, the longer it usually takes, but there is a limit. You have heard the term “paralysis of analysis”.  Time is money and taking too much time to make decisions costs money. On the other side of the coin, you can make decisions too fast. In that case, you do not give yourself enough time to consider all the options. Sometimes people are so focused on getting another item off their “To do” list that the driving force to make the decision is that instead of the driving force being to make a good decision.

Culture & Personalities

There are also decision-making considerations that have nothing to do with you. They are external. Things like the culture of the organization that you are working in, the constituents that are judging your decisions, and the process. making a decision

Every organization has a culture that is unique.  No matter what decision-making skills you have, you must consider the culture of that organization for your decisions to succeed.  Some organizations will not accept a decision if it is made too quickly.  Others look at the speed of a decision as being the most critical factor for success.  If you work at a fire station, quick decisions are very important, while quick decisions in a pharmaceutical company are not.  Be aware of the decision-making culture in your environment to give your decisions the best chance for success and in turn giving your career the best chance to progress.

Just like organizations have different cultures, people have different behavior types.  Very few decisions are made that do not impact other people, the people you report to, your peers, the people that report to you, family members, friends, basically your constituents.   The success of your decisions will be directly influenced by the people impacted. You must consider your constituents as a direction is chosen. How will they react? What actions will they take? How will this affect them emotionally?  Your constituents will judge your decisions and your long-term success will depend on those judgments.

Have you ever heard the phrase, “there is a right way and a wrong way to do something?”  That is true in the decision-making process as well. Your decision-making process can make or break your decisions. As I explained above, organizations have a culture and people have different behavior types.  If those entities inherently respect the process you use to make a decision, your decisions will be more successful and your value to the organization will increase.

Decision Evaluation

Finally, don’t spend time regretting or gloating over a past decision.  That is not productive, but assessing a decision with the intent to learn is.  Set a realistic assessment time in the future and do a postmortem review to evaluate how the decision was made, was the outcome good or bad, should you continue in the chosen direction, and what would you have done differently if you had to do it again. The intent is not to beat yourself up or pat yourself on the back. At the time a direction is chosen, do everything you can to make the chosen direction work.  Every bad decision I have made has helped me make better decisions in the future. Bad decisions are opportunities to learn and if that is your mindset, you will get better at decision making, and in turn, help advance your career.  At the end of the day (my kids love it when I use that phrase) you must understand the information, filter out what is critical to the decision, assess the risk, and understand your constituency.  There are tools you can use to improve your decision-making abilities, but for now, work on one thing; developing the internal fortitude necessary to shoulder the responsibility of making a decision and then “JUST MAKE THE DECISION”  Good luck.

Learn More

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.

 

 

UL Materials | Closed Cell Sponge Rubber

Many users of sponge rubber products for sealing are unaware that UL guidelines dictate that when adhesive is applied to sponge rubber the chemistry has been changed. Essentially, this creates a new product which must pass specific tests to be added to a list of approved UL materials.

UL Listed Closed Cell Sponge with AdhesiveTo help solve this issue, CGR Products has three UL listed closed cell sponge and adhesive combinations that are listed to UL JMLU2 standards and are suitable for UL50E applications.

In this guide, we will break down our three combinations to help you identify the best solution for your application.

8002/702P

UL Listed Closed Cell Sponge Stripping with Adhesive

8002/702P is considered our “high-end” combination utilizing greater temperature ratings and high-performance adhesive. 8002 sponge is pure EPDM sponge. It has 2A2 ASTM designation with a density of 9 +/-2. The 702P adhesive is a heavy mass 7mil (liner side) double coated acrylic tape.

5031/9824

5031/9824 is considered our “mid-grade”.  5031 sponge is a blend of EPDM/CR/SBR.  It has 2A1 ASTM designation with a density of 6 +/-2.  The 9824 adhesive is 3mil (liner side) high strength double coated acrylic tape.

DK1111/9816

DK1111/9816 is considered our “general purpose” combination and also utilizes a rubber based adhesive.  DK1111 sponge is a blend of EPDM and Neoprene.  It has 2C1 ASTM designation with a density of 5.   The 9816 adhesive is 3.5mil (liner side) double coated high tack rubber-based tape.

UL Materials from CGR Products

These UL listed closed cell sponge with adhesive combinations are commonly used for sealing and gaskets in electrical enclosures, control panels, appliances, and many other applications.  CGR Products offers lamination, slit to width, sheeting, and die cutting for all of your converting needs.  Our UL listed Products are labeled and shipped with the Recognized Component Mark,  UL Listed Closed Cell Sponge with Adhesive Recognized Component

 

For a further in-depth look at our UL listed Products, download our latest eBook by clicking here.

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

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.

Material of the Month: Rogers Corporation PORON

Here at CGR, we stock a wide variety of specialty materials, from unique adhesive solutions and flexible rubbers to custom-engineered fibers. During our Material of the Month blog series, we’ve been showcasing some of our favorite, most popular materials, outlining their unique features and exploring common applications.

This month, we’re highlighting our extremely versatile Rogers Corporation PORON®

PORON products have these great benefits:

  • A higher compression set resistance for durable, long-term performance.  Good for gasketing, sealing, and cushioning.
  • Micro-cellular construction that contains no plasticizes or residual chemicals.  The material will not become brittle and is non-corrosive to metal.
  • Meet several flammability requirements of UL HBF and MVSS 302.
  • Available in many densities and thicknesses.
  • Good chemical resistance
  • Die-cuts neatly and accepts a broad range of adhesives.
  • Ideal for shock and vibration absorption in sensitive electronics.

Visit the Rogers Corporation website for more information on all the PORON® materials available.

PORON and CGR Products:

CGR Products is a Rogers Corporation preferred converter.  At CGR Products we stock many grades of PORON® and several thicknesses.  CGR commonly adds adhesive then fabricates finished parts by means of die cutting, waterjet cutting, knife cutting, rotary cutting, and slitting.

Adding adhesive to PORON® makes for great kiss cut applications.  Other methods to note; if larger window frame gaskets can be dovetailed or foldout, this will allow a much greater utilization of material and substantially reduce cost.

Using PORON for Your Application

As flexible material specialists, the CGR team offers years of experience in converting PORON® into gaskets and components. Our in-house precision cutting services include rotary and flatbed die cutting, kiss cutting, slitting, splitting, knife cutting, and more.

PORON® 4 piece dovetailed gasket. This eliminates the center waste if this was cut as a 1 piece gasket.

Three dimensional tray made from multiple plies of PORON® to be used as a shock mount for heavy equipment touchscreen displays.

 

 

 

 

 

 

 

 

 

 

For more information about PORON®’s unique applications and fabrication possibilities, visit our PORON material page.

 

 

Three Capabilities You Might Not Have Known About CGR Products

Here at CGR Products, we use a variety of cutting and fabricating capabilities on a daily basis.  However, we do some fabricating that might seem “out of the norm” from our core manufacturing.  In this article we will highlight three things you might not have known about CGR Products capabilities.

Metal Fabrication Capabilities

All three CGR Products facilities have the ability to fabricate high volume metal parts.  Each location has die cutting presses capable of cutting thinner gauge metals, typically in roll or sheet form.  In addition, our Waukesha, WI plant has 2 abrasive waterjet machines capable of cutting many types of thicker metals.  We produce specialty gaskets including head gaskets with fire rings, and metal encapsulated gaskets.  Watch our video below of a high volume metal composite being die cut.

Displays and Lettering

CGR Products has the unique capability of fabricating foam lettering and displays in high volumes.  These items can be plain, adhesive backed, or magnetic backed.  We can cut foam up to 9.00″ thick in a variety of colors and densities.  We work directly with the retail store design firms to meet their specific display goals.  Examples of our work can be found in Grocery Stores and retail shops in the Southeast.   Visit our Open and Closed Cell Foam Materials page for examples of the types of foams we work with.

waterjet cut xlpe display capabilities

Foam Perforation

CGR Products has the specialized capability of wide format foam perforation.  Foam perforation is typically found as underlayment in sporting fields to allow for water drainage.  Our perforation process can cut material up to 60″ wide and run roll to roll.  Our unique process allows the slugs to be removed while cutting, saving time for the end user.   Once perforated, the rolls are plastic wrapped and labeled.  Rolls are typically shipped in truckload quantities ready for the end user to install.

foam perforation

Learn More

With over 140,000 square feet of manufacturing and warehouse space and over 100 top-quality machines, CGR serves a diverse range of clients. To learn more about our capabilities, click around our website or visit our Sample Gallery to view a portfolio encompassing many of the industries we serve.