22nd Feb 2023

Digital Knife-Cutting to Shape and Cut Foam To Size

Zouch uses state-of-the-art cutting technology to manufacture and convert various foams, fabrics and sponge rubbers.

Using this digital technology, Zouch streamlines the production process and copes better with increasing numbers of short runs and customer demand. We use digital knife-cutting technology because of its ability to create bespoke shapes, no matter how complex our customer's requirements are.

Advantages of using a Digital Knife Cutter

  • High precision

  • Save on material

  • Cut to bespoke shapes

  • More flexible and efficient

  • More environmentally friendly

  • Different types of knife cutting (vibrating, round, etc.)

  • No soot and a cutting speed 3-4 times faster than a laser

Unlike traditional die-cutting, parts are cut to the highest quality and tighter tolerances, with the cutting of the edges remaining consistently high without the need to maintain and manage expensive die tools.

Before parts are produced in bulk, they are often presented to the customer as samples for approval. Digital cutting technology allows us to create perfect prototypes. After approval of samples, Zouch can start mass-producing at the push of a button, creating finished parts that mirror the original prototype.

three pieces of thick grey polyethylene foam piled together that has been cut using a cnc cutting knife
three pieces of thick grey polyethylene foam piled together that has been cut using a cnc cutting knife
two pieces of thick grey polyethylene foam piled together that has been cut using a cnc cutting knife

These examples are cut from our ZOUCH eFoam XLPE 30, a fine-cell chemically cross-linked closed-cell Polyethylene block foam.

Digital knife-cutting is widely used in packaging to create bespoke shapes for any type of product needing foam protection or display. Using a CNC machine, we automatically cut various foam materials precisely to shape accurately and detail foam to specification. That means there’s no need for moulds, with a smooth cutting edge and high processing accuracy.

Frequently asked questions

What is a digital knife?

A CNC (Computer Number Controlled) knife-cutting machine is a digital cutting system used for its high-precision cutting of semi-rigid and heavy materials. The cutting movement is controlled by a computer and allows for accuracy and a smooth cutting edge.

What are the advantages of a CNC cutting machine?

Using a CNC cutting machine greatly improves accuracy, reduces excess material, and improves the foam edge's quality.

Are there any disadvantages?

A CNC cutting machine is largely only used for certain thicknesses of foam, fabrics and sponger rubbers. It’s usually used for heavy or semi-rigid materials.

However, at Zouch, we’re not just a specialist manufacturer in digital cutting; we split, saw, rout, die-cut, waterjet cut, butt-weld, laminate, adhere, thermoform or compression mould, too!

That’s because we know there is no one-size-fits-all for foam production, and each project and challenge differ. We cut all our foams to size to create even the most complex shapes and sizes, whether in foam sheets, blocks or rolls.

Get in touch with a member of the Zouch team today to discuss your latest project. We’re always happy to offer non-biased advice and help you choose the right type of foam for your product.

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