Component Foams Specifically Engineered for Automakers

Guest Author: Isabell Wright, Armacell .

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

To go along with the Component foams, Avery Dennison has put together an in-depth adhesive bonding study which can be found Here.

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.  For your next foam project, Contact Us today.

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.

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.

CGR Products News Release

CGR Products News Release: Growth Leads to a 30,000 sq ft Expansion and New High Volume Manufacturing Machinery

Click Here to read the full news release.

To Fuji or not to Fuji Test your Gaskets, That is the Question

Many variables can affect gasket sealing such as internal pressure, temperature, gasket design, and flange load.  Sometimes it is necessary to dig a little deeper into the actual sealing picture when a difficult or critical sealing situation is encountered.  In this article, we will explore a process we call “Fuji Testing”.

How Fuji Testing Works

Fujifilm Prescale is a polyester based film that contains a layer of tiny microcapsules. The application of force upon the film causes the microcapsules to rupture, producing an instantaneous and permanent high resolution “topographical” image of pressure variation across the contact area.  The use of this tactile sensor film is one method CGR Products uses to help customers see a “Static” picture of how the gasket is sealing in the current application.

We place the Fuji film between any two surfaces that touch, mate or impact. Apply pressure, remove it, and immediately the film reveals the pressure distribution profile that occurred between the two surfaces.  Like litmus paper, the color intensity of the film is directly related to the amount of pressure applied to it.  The greater the pressure, the more intense the color.

Analyzing the Fuji Data

The principle way in which CGR Products uses Fuji film is to determine if the current gasket design is producing an acceptable seal to satisfy the customers’ requirements.   In our example below, you are looking at a currently designed gasket where its highest pressure points are at the bolt holes.  The bolt pressure points left a softer area in the middle of the flange.

Making Recommendations

If it is determined that the sealing pressure revealed by the Fuji film is not acceptable, CGR Products can use the film data to determine a possible revised gasket design.  These tests can also reveal that a material change is all that is needed to satisfy the sealing requirements.  Using the same example, this is CGR Products proposed design and material change after Fuji analysis.

Learn More

To answer the question as to whether a Fuji analysis is right for you, Ask yourself if the potential warranty cost to your company is worth the time and effort.  Let CGR Products help with your sealing issues so we can work together to solve potential warranty problems before they occur.  Feel free to contact us with questions or dig deeper into our capabilities by clicking on our website.

Material of the Month: Felt

CGR Products stocks a large variety of materials for a wide range of applications. Flexible rubber sheeting, adhesive solutions, and fiber materials are just a few of our specialty options.

Our Material of the Month series spotlights some of our favorite materials and their unique applications. This month, we’re discussing Felt.

What is Felt?

Felt is a very versatile and resilient industrial fabric that is manufactured using different processes.

Needle Punch Process:

A fiber such as polyester is interlocked using a machine with thousands of needles moving in an up and down motion.  Heat is then applied using a calendar roll to make a smoother surface and remove fuzziness from the felt.  Calendaring can also be used to produce a firmer sheet.  A binder can be added to felt that needs to be thermo-formable.

Woven:

Wool or wool blended with other yarn are woven into cloth and then felted using steam and pressure to interlock the fibers.

Pressed:

Wool fibers or wool blended with other fibers are pressed together with steam and pressure that allows the fibers to naturally interlock.

Material Terminology

• Denier: weight in grams of one single thread of fiber 9,000 meters long.
• Loft = thickness
• Hand: the feel of the felt.
• Weight: ounces per square foot or grams per square meter.

General Applications

Automotive Applications

Vibration dampening gaskets, wheel well liners, trunk and deck liners, under carpet padding, and noise absorption.

Appliance Applications

Vibration dampening gaskets, noise reduction, and lint and air seals.

General Industrial Applications 

Industrial sander backing pads, floor protection pads, and oiler pads for slitting and friction applications.

Using Felt for Your Application

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

For more information about applications and fabrication possibilities, visit our Materials Page.  To discuss any Felt options for your next project, please reach out to our team today.

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.

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.

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.

Rotary Die Cutting vs. Flatbed Die Cutting: Which Should You Use?

Die cutting is frequently used to fabricate unique shapes from rubber, plastic and foam materials.

Before starting a die cutting project it is important to discuss all specific project requirements — including whether rotary die or flatbed die cutting is the best fit for the job. Each cutting method has its own distinct benefits based on production size, costs, and material.

What is Rotary Die Cutting?

Main Benefits: Holds tight tolerances and ideal for kiss cutting

Best Used for: High-volume orders

How It Works: Rotary die cutting, a highly accurate cutting method, is very cost effective on high-volume orders and produces less waste compared to other methods. As shown in the video, the machine is fed a roll of material which is then passed through the rolling die. This cuts the desired shape from the material and the waste is disposed of into a catcher.

What is Flatbed Die Cutting?

Main Benefits: Provides a more cost-effective option with lower tool and die costs

Best Used for:  General cutting and low-volume orders

How It Works: With flatbed die cutting, material shapes are stamped out using steel rule dies and hydraulic presses. This method allows for easy hole removal and web removal from parts, along with quick changeover times to increase efficiency.

Die Cutting with CGR Products

CGR’s team of engineers makes sure to match your project’s needs with the right die cutting machine for the job. The products we die cut from a variety of flexible non-metallic materials can be supplied in continuous rolls, sheet form, or individual parts for your unique application.

Ready to get started? Visit our Supplier Material Library to find your material and contact us about your next project.

Die Cutting vs. Waterjet Cutting: Which One Should You Use for Your Project?

More cutting methods are available today than ever before. While friction sawing used to be the primary industrial material cutting option, there are now nearly a dozen viable choices.

Not all cutting methods are created equal — which isn’t to say that one is categorically better than another, but rather that they all have their own strengths. To ensure the accuracy, efficiency, and cost effectiveness of your next project, each designated cutting method specified for a particular part should be a major consideration starting in the design phase.

Two of the more common cutting methods that manufacturers offer today, die cutting and waterjet cutting, each have benefits that are suited to particular needs.

Waterjet Cutting

Waterjet cutting, exactly as its name implies, uses highly pressurized jets of water to cut through soft materials.  When harder materials such as metals or plastics are needed, abrasive mineral can be added to the water to enable the waterjet to cut these materials as well.  This method offers several benefits over die cutting and other cutting methods.

Clean Cuts

Primary among these benefits are the clean cuts that the process generates.

Many companies consider waterjet cuts to be “finish cuts,” aesthetically  acceptable cuts that require no secondary finishing processes. This is important for applications where financial budgets or time constraints are a concern — finishing processes add both time and money to your project.

Low Heat

The second important benefit of waterjet cutting is that it generates little heat, and transfers even less to the material being cut. This is important for a number of reasons:

• It allows for the use of waterjet cutting on meltable and flammable materials — such as plastics, laminates, acrylics, and more — that can’t be laser or plasma cut
• It prevents the release of heat-generated toxins into the workplace
• It doesn’t create heat affected zones on cut parts, thereby eliminating a secondary finishing process that laser or plasma cut parts often require

Tolerances

Waterjet cutters are able to maintain tighter tolerances in their cuts because the cutters are controlled by highly accurate computer software. Additionally, the process creates no mechanical stresses in the material being cut, eliminating the loss of tolerance caused by warping.

Die Cutting

Die cutting is a very common method of cutting, wherein sheets of material are stamped  with a die in order to create the required part.  Die cutting  carries many benefits:

Speed

Most die cutting processes, including rotary die cutting and progressive die stamping, are continuous processes. In these processes, rolls of material are continually fed into the equipment and stamped parts are continually output.

Simple parts in particular can be produced at great rates. Simple flat cogs, as an example, can be completed in one second with a single stamp. More complicated parts can be quickly manufactured by utilizing a progressive die stamping process.

Uniformity

Particularly important for large volumes of identical components, die cutting creates parts with a high degree of uniformity. Punching a part out with one swift movement prevents variances that can occur in processes that cut a shape around the edges. Tool and die fatigue can occur, but a quality stamper will know his machines and replace affected equipment long before they can impact the quality of the parts.

Cost

Because of its ability to create very high volumes of parts with a high degree of uniformity, die cutting is a relatively inexpensive method of cutting. The high output reduces time and, therefore, labor costs, and uniform products reduce losses related to quality assurance.

Additionally, die cutting equipment is fairly standard — many companies perform die cutting, so competition keeps costs reasonable. Tool and die manufacturing can be costly, but high volume part orders can easily negate that one-time expense.

Cutting with CGR

Over the course of more than  50 years, CGR Products has developed expertise with a range of different cutting methods — not only die and waterjet cutting, but also knife cuttingand more. Not every method is the same, nor are they all suitable for any project.

To learn more about cutting methods and other important design considerations, download our eBook, 5 Common Design Mistakes & How to Avoid Them.