The Custom Fabrication Process: From Concept to Component

Custom fabrication is more than just cutting shapes; it is a high-tech manufacturing discipline that transforms raw materials into functional industrial parts. At CGR Products, we follow a rigorous multi-step process to ensure every gasket, seal, and component meets exact specifications.

Step 1: Design and Engineering Consultation

Every successful project begins with a deep dive into the application’s requirements. Our engineers work with you to analyze:

  • Environmental Factors: Will the part be exposed to UV, extreme temperatures, or chemicals?

  • Tolerance Requirements: Does the application require standard tolerances or high-precision accuracy (e.g., $\pm$ 0.005″)?

  • Material Selection: Choosing from our extensive inventory, including 3M adhesives, Rogers PORON® foams, and various elastomers.

Step 2: Prototyping and Toolless Development

Before moving to high-volume production, we often utilize “soft-tooling” or toolless methods to create functional samples.

  • Waterjet Cutting: Ideal for thick materials (up to 9″) or complex shapes where heat distortion must be avoided.

  • Digital Knife Cutting: Perfect for rapid prototyping of thin-gauge materials without the upfront cost of a steel rule die.

  • CAD Optimization: We use advanced software to ensure the digital design is optimized for maximum material yield (nesting).

Step 3: Material Preparation and Lamination

Many precision-converted parts require multiple layers. In this stage, we combine substrates with high-performance adhesives.

  • Hot Roll Lamination: Using heat and pressure to ensure a permanent bond between the material and the pressure-sensitive adhesive (PSA).

  • Custom Slitting: We slit master rolls down to the specific width required for the final production run, ensuring zero waste at the edges.

CGR Products kiss cutting

Step 4: Precision Converting Services

Depending on the volume and complexity, we select the most efficient cutting method:

  • Rotary Die Cutting: Best for high-speed, high-volume runs, especially for kiss-cutting parts onto a roll for easy “peel and stick” application.

  • Flatbed Steel Rule Die Cutting: A cost-effective solution for large-format parts or medium-volume production runs.

  • Through-Cutting: Cutting through both the material and the liner to produce individual, loose pieces.

Step 5: High-Tech Quality Inspection

Quality is non-negotiable. We utilize a suite of advanced inspection tools to verify every dimension:

  • Virtek LQC Scanners: This laser inspection system compares the finished part directly to the CAD file in seconds, ensuring 100% accuracy.

  • SPC (Statistical Process Control): We monitor production data in real-time to maintain consistency throughout the entire run.

  • First Article Inspection: Before the full run begins, the first parts are meticulously checked against the original blueprints.

Step 6: Value-Added Finishing and Kitting

The custom fabrication process doesn’t end at the cutting table. We offer several secondary operations to streamline your assembly line:

  • Kitting: Grouping multiple different parts into a single package for easy technician access.

  • Custom Labeling: Adding barcodes or part numbers directly to the components or packaging.

  • Specialized Packing: Ensuring parts are shipped on rolls, sheets, or in individual bags according to your assembly requirements.

Since 1961, CGR Products has been providing high-quality, precision-detailed custom fabrication components for our customers in the manufacturing industry.

CGR Prodsucts Custom Fabrication

We have over 190,000 square feet of manufacturing space in 4 locations that house over 100 different workstations that can be used to produce any volume of custom fabricated parts.

These parts can be made from a wide variety of materials such as PVC, graphite, fiberglass, Mylar, Plexiglas, polycarbonate, urethane, PTFE, rubber, PEEK, neoprene, and other materials that can be custom designed to meet your specific needs. No matter what material your part is made of, you can rest assured that it will undergo the most meticulous quality control process in the industry.

At CGR Products, we strive to maintain the best possible quality control and employ a full lineup of tools and procedures that ensure every part we ship surpasses expectations. Custom fabrication services that we offer include:

Beaded Gaskets

Beaded gasketing is an excellent way to improve how well the gasket seals. This process involves applying a high-performance, resilient elastomer to the outer surface of the gasket. This method effectively blocks potential leak paths and increases the strength of the gasket in precisely the points where the load is the largest.

Distributed Items

CGR Products supplies many molded parts as distributed items from both domestic and overseas manufacturers.

 

For more information about our custom fabrication services, contact CGR Products.