Comments Off on 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.
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.
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.
Comments Off on 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.
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.
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.
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
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.
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.
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.
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.
Comments Off on Cutting vs. Converting – What’s the Difference?
Don’t Get Tangled Up in Terminology
The CGR team gets a lot of requests for cutting, converting, and fabricating. Fortunately for our customers, we do it all. As far as we’re concerned, these terms refer to the same process — the process of transforming a raw material into a precision component for your part.
If you participated in Manufacturing Day this month, you may have gotten a chance to dig into some of the processes and services from manufacturers across the country. We’re happy to break down some of our cutting capabilities right here, right now.
We specialize in flexible, non-metallic materials at CGR Products — that means custom parts, shapes, sizes and forms for markets of all kinds, cut from an immense range of elastomer, rubber and related thermoplastic materials. Each and every material — and family of materials — comes with specific capabilities to accommodate all types of industries.
Cutting, Converting or Fabricating?
As we said above, we do it all. Some of the specific methods we use to cut and convert materials at CGR include:
Die Cutting: Both rotary die cutting and flatbed die cutting are optimal for high volumes and precise tolerances.
Kiss Cutting: This special type of cutting (or converting) transforms sheets of material into sheets of parts that can be removed individually from a backing or liner.
Knife Cutting: This is one of the fastest methods for producing a part. It’s great for prototypes.
Slitting and Splitting: A shearing process, slitting or splitting takes a large roll and trims it into narrower or thinner rolls or sheets.
Waterjet Cutting: The accuracy and precision of a water jet cutter is ideal for soft materials.
Don’t forget that we also offer custom manufacturing and fabrication for projects that demand molding, extrusion. laminating and beaded gaskets.
Check out all of our available services, or call the team to discuss your particular project today. We look forward to cutting, or converting, or fabricating with you!