Which tool for bulk cutting underlay.

[caswell239]

Hey all, my dad is semi retired and has a gig making these gaskets for mines that he makes out of carpet underlay. He draws squares on the underlay then hand scissors them, then uses hole saw and cuts out the center. He's made 3000 this way and had at least 10,000 more for this mine and maybe a few more mines interested. Looking for your thoughts on what would be fastest way of cutting the squares. I was thinking power scissors. He can't use exacto knife because it rips. He has used electric meat cutter. Any other ideas? You guys are a brilliant source of info! Thanks in advance!


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[Empty Pockets]

If memory serves, there is a Bosch tool made for cutting multiple layers of fabric or foam rubber. This might work:

http://www.toolup.com/Bosch-1575A-Foam-Rubber-Cutter

 

[waynem]

Look a getting a "Rule Die" made. Look it up. You don't say how big the part is so may not work for the application

 

[caswell239]

Something like this.


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[balrog]

Would a nichrome wire hot knife setup work on that material?

 

[Larryjones]

I bought some foam rubber a while back at a bulk type store, they cut it out with an electric carving knife.

 

[APEowner]

Roughly how big are the final parts?

 

[caswell239]

One square foot, then like a 5" inch hole cut from the center.


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[PCustoms]

Company is out of Buffalo NY and makes anything from manual to full CNC cutters that should work for this material

http://www.eastmancuts.com

Visited them a while back and picked up a simple rotary cutter and track for carbon fiber.

Also google rotary shear, there are small rechargeable ones that may work for the circles.

 

[jake00]

Look a getting a "Rule Die" made. Look it up. You don't say how big the part is so may not work for the application

I second this,

 

[machine_punk]

If memory serves, there is a Bosch tool made for cutting multiple layers of fabric or foam rubber. This might work:

http://www.toolup.com/Bosch-1575A-Foam-Rubber-Cutter

+1 on this. This is how clothing manufacturers cut out dozens of pieces of cloth at the same time.

My other thought is the device called a clicker punch press. This is the same device they use to punch out parts of boots, shoes, and leather upholstery. Get a die/cutter made to the size of the piece you want to cut and punch a few out every few seconds. The size you are talking about, with the material you are using, may allow you to punch 4 at a time.

KDub

 

[FullRaceMerc]

Company is out of Buffalo NY and makes anything from manual to full CNC cutters that should work for this material

http://www.eastmancuts.com

Visited them a while back and picked up a simple rotary cutter and track for carbon fiber.

Also google rotary shear, there are small rechargeable ones that may work for the circles.

I was in a cat furniture factory where they used one of these to cut thick stacks of carpet. You know, the carpet covered plywood structures with places to hide or climb. They had the pattern on the top piece & cut the stack all at once. The stack was on a large table with a smooth top. The foot of the tool slid on the table & the stack stayed in place. It looked like it made quick work of the job. It seems like it might do for your task.

 

[risc]

Out source it to a local die cutter. Given the volume it's going to be pretty cheap per piece.

 

[Packard V8]

http://www.toolup.com/Bosch-1575A-Foam-Rubber-Cutter

The "list $653" is nuts. Even the $333.73 seems high for what it is.

I've got one of these in mint condition. You might PM me with an offer.

jack vines

 

[Brian_WK]

I use an serrated electric carving knife for cutting all my thicker foam. Make sure it is good and sharp and it will cut like butter. You can even mount it to a table with the blade facing up and a center pivot point to spin the foam on like a scroll saw. One pivot for the outer circle and one pivot for the inner circle on each side of the blade.

Otherwise a rotary cutter and a nice self healing cutting mat will work well if its under 1/2inch thick.

Brian