mANUFACTURING PROCESSES
Die-Cutting & Assembly
Pro-Form produces die-cut parts and packaging products from non-metallic materials including foam, felt, rubber, plastic, paper and gaskets. We also design seals and coating masks. Our clients can choose from a large assortment of die cutting equipment that ranges from high-speed computer-controlled presses to large roller presses that are capable of producing die-cut parts as large as 32” x 180” (32 inches by 180 inches).
Assembly:
Assembly services at Pro-Form include “kitting.” Your product packaging items are completely ready to use the second they arrive on your factory floor. “Kitting” product packaging can involve hot-air welding, heat bending, gluing, laminating, riveting, shrink wrapping, and mechanical fastening.
Pro-Form’s advantages:
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VOLUME: The sheer amount of foam we can die-cut is unmatched.
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UNMATCHED: There are only 3 die-cutting machines in the world with our capabilities; we own 2 of them. We have the ability to die-cut parts over 200” long.
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EXCEPTIONAL: Pro-Form offers value-added assembly — efficiency expertise, skilled technical staff, logistics and cost-effective solutions. The volume we handle is second to none.
Frequently asked questions
What is die-cut packaging?
Die-cut packaging is a process that cuts precise shapes from materials like foam or plastic to create protective inserts.
It is used to:
- Secure products in place
- Prevent movement during shipping
- Improve packaging consistency
What materials are used in die-cut packaging?
Common die-cut materials include:
- Foam
- Felt
- Rubber
- Plastic
- Paper
- Gaskets
Material selection depends on product weight, fragility and shipping conditions.
How does die-cut packaging improve efficiency?
Die-cut packaging improves efficiency by ensuring consistent product placement and reducing handling time.
Benefits include:
- Faster packing
- Reduced damage
- Improved organization
Can die-cut packaging support automation?
Yes. Die-cut packaging is often used in automated manufacturing because it ensures consistent part orientation and fit.
What is the best packaging for preventing shipping damage?
The best packaging depends on the product type:
- Foam inserts - best for fragile components
- Thermoformed trays - best for repeatable handling
- Wood crates - best for heavy equipment
How do you design custom packaging for a product?
Custom packaging design typically follows these steps:
- Analyze product dimensions and weight
- Evaluate shipping and handling conditions
- Select materials
- Create CAD designs
- Prototype and test