When you’re designing custom gaskets, pads, or thermal interface components, there are several cutting methods available — die cutting, waterjet cutting, laser cutting, and knife cutting. Many assume the choice is mostly about production volume, but in practice about 80% of the decision comes down to the material itself: its thickness, density, and how it behaves under each process.
And while die cutting can handle the majority of jobs, sometimes specialized methods like waterjet, laser, or knife cutting become important tools in the toolbox for unique materials or geometries.
1. Die Cutting — The Workhorse for Most Applications
Die cutting uses a steel rule die pressed into the material like a cookie cutter.
Best for:
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Thin, uniform materials — generally ≤0.250″ thick.
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Medium to high production volumes — dies pay for themselves quickly.
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Dense rubbers, adhesive-backed foams, and films that shear cleanly.
Strength:
Die cutting is extremely versatile and covers most standard gasket and pad work. If the material and thickness allow, it’s usually the fastest, most cost-effective choice.
Limitations:
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Very thick sections (over ~0.25–0.50″) may not cut cleanly.
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Extremely soft foams may distort rather than shear.
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Brittle or layered composites can split under press force.
2. Waterjet Cutting — Great for Thick, Dense, or Tool-Resistant Materials
Waterjet uses a high-pressure stream of water with abrasive — no heat involved, so adhesives and sensitive materials stay intact.
Best for:
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Thick materials — easily cuts silicone, rubber, foam over 1″ thick.
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Materials that don’t tolerate the compression of die cutting.
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Prototype and short runs — no tooling needed.
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Complex shapes in tough materials.
Limitations:
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Very soft or layered materials — water pressure can cause delamination or fraying.
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Ultra-thin films — may flutter or distort.
3. Laser Cutting — Precision for Thin, Heat-Tolerant Materials
Laser cutting shines when you need fine detail and crisp edges.
Best for:
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Thin materials — films, paper, plastics, thin foams.
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Complex, intricate geometry with micro holes or tight inside corners.
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Quick-turn prototypes without tooling.
Limitations:
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Thick sections — lasers slow and edges degrade beyond ~0.125–0.250″.
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High-temperature silicones, PTFE, or thermal gap fillers — can char or emit fumes.
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Foams and laminates — risk of edge discoloration.
4. Knife Cutting — Flexible and Tool-Free for Prototypes & Simple Runs
Knife cutting (digital or CNC knife tables) uses a sharp oscillating blade.
Best for:
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Prototypes and low volumes — no hard tooling cost.
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Softer foams, thin rubber, and adhesives that cut well with a blade.
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Quick setups for simple outlines.
Limitations:
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Tight radii and sharp interior corners — blades can drag, deflect, or cause material to fold over.
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Very thick or dense materials — harder to cut cleanly.
The Real Decision Driver: Material & Thickness
While part volume and geometry matter, the material and its thickness decide most of the cutting method:
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Die cutting can handle the majority of standard jobs.
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Waterjet adds range for thick, dense, or exotic materials.
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Laser is ideal for fine detail in thin, heat-tolerant materials.
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Knife cutting is a fast, tooling-free option for prototypes and soft materials.
By knowing your exact material, thickness, and performance needs, we can select the process that delivers clean edges, stable dimensions, and cost efficiency.
Bottom Line
Die cutting is the backbone of most custom gasket and pad production. But waterjet, laser, and knife cutting expand the toolkit — letting us handle thick silicones, delicate laminates, high-temp materials, and complex one-off jobs with precision.
Need advice on how to cut your part? Share your material and drawing — we’ll recommend the best method and can quickly produce prototypes.