Rotary Die Cutting Services & Manufacturing

Hi-Tech Products is a precision rotary die cutting manufacturer serving medical, electronic, aerospace, and industrial customers nationwide. With more than 30 rotary die cutting presses — including 8 state-of-the-art servo presses handling widths up to 24″ — we deliver high-volume, high-precision die cut parts from certified cleanrooms in the U.S. and Mexico. As a 3M Preferred Converter and FDA-registered, ISO 13485:2016 and ISO 9001:2015 certified manufacturer, we combine engineering expertise with the material access to support even the most demanding die cutting projects.

What Is Rotary Die Cutting

Rotary die cutting is a high-speed converting process that uses cylindrical dies to cut, laminate, and shape flexible materials as they pass continuously through a press. It’s the preferred method for high-volume production runs that require tight tolerances, repeatable accuracy, and inline finishing — making it ideal for adhesive components, medical device parts, gaskets, labels, and electronic assemblies.

Rotary Die Cutting Capabilities

Our die cutting services go beyond basic cutting. Every process below can be performed in certified cleanrooms, often combined inline on the same press pass.

Island Placement with Electronic Registration

We laminate pre-cut adhesive shapes onto material during the die cutting process, positioning adhesive only where it’s needed. Adhesive free substrates can also be island placed. Optical sensors control registration within tight tolerances, minimizing scrap and enabling registration to preprinted substrates. Hi-Tech has many state-of-the-art servo rotary presses capable of this process in certified cleanrooms.

• Performed in-line with laminating, die-cutting and pouching
• Minimizes or eliminates scrap
• Register within tight tolerance requirements
• Optical sensors control registration
• Register to preprinted substrates

Inline Pouching

Parts can be packaged inline as they’re die cut, with pre-printed heat seal or cold seal pouching. Pouch materials include foil, film, paper, and Tyvek.

• Heat Seal – creates moisture / vapor barrier
• Cold Seal – Fastest, Lowest Cost Pouching Option
• Island placement of heat seal patterns
• Foil pouching with controlled temperature, humidity and lighting
• Devices converted and pouched inline
• Foils, film, paper, Tyvek all in-stock
• Hi-Tech can package inline with both cold seal pouching and heat seal pouching materials

In-Line Flexographic Printing

We offer inline flexographic printing across our U.S. and Mexico presses, including preprinted release liners, direct printing onto die cut parts with electronic registration, and zone or flood coating of specialty coatings.

• Pre-print your release liner; either registered or random repeat
• Inline Flexo Print directly onto your die cut parts with electronic registration
• Zone coat and flood coat a wide range of specialty coatings

Multi-Layer Laminating

Our rotary die cutting presses laminate flexible substrates together using heat or PSA — without entrapping air or contaminants and not stretching the substrate. — supporting up to 12 layers across single or multi-station configurations.

• Single station presses
• Multi-station presses
• Capable of laminating up to 12 layers

Custom-Built Rotary Presses

Hi-Tech is capable of designing and building one-of-a-kind presses if needed to meet your unique requirements and applications.

• Island placement with electronic registration
• Handling widths up to 24″ wide
• Presses in certified clean rooms

Industries We Serve

Our rotary die cutting manufacturing supports critical applications across:

• Medical — components requiring cleanroom converting and traceability
• Electronics & Automotive — precision parts for demanding tolerance environments
• Aerospace & Military — mission-critical materials and specifications

Why Choose Hi-Tech Products for Rotary Die Cutting

Choosing the right die cutting process and manufacturing partner directly affects product quality and cost. Hi-Tech Products evaluates each project to apply the most efficient converting approach, backed by:

• FDA registration
• ISO 13485:2016 certification
• ISO 9001:2015 certification
• 3M Preferred Converter status for competitive material sourcing
• Certified cleanroom manufacturing in the U.S. and Mexico
• American-engineered quality at offshore pricing

Whether your project requires rotary die cutting, flatbed die cutting, or precision laser cutting, our full range of converting capabilities is available under one roof — all performed in certified cleanroom environments.

Request a Rotary Die Cutting Quote

Ready to discuss your project? Contact Hi-Tech Products to request a quote or prototype from our die cutting manufacturing team.

Rotary Die Cutting FAQs

What materials can be rotary die cut?
Hi-Tech Products die cuts a wide range of flexible materials, including adhesive-backed films, foams, foils, Tyvek, paper, and laminated substrates. As a 3M Preferred Converter, we also have direct access to specialty adhesive and material lines for applications with specific performance requirements.

Can rotary die cutting be done in a cleanroom?
Yes. All of our die cutting capabilities — including island placement, lamination, and pouching — can be performed in certified cleanrooms, making the process suitable for medical device and diagnostic applications.

What size parts can your rotary presses handle?
Our servo rotary presses handle material widths up to 24 inches, with up to 14 stations for multi-step inline processing such as laminating, die cutting, printing, and pouching in a single pass.

Do you build custom die cutting presses?
Yes. When a project requires equipment beyond standard configurations, Hi-Tech Products designs and builds custom, one-of-a-kind rotary presses engineered to the application’s specific requirements.