Precision Die Cutting Services for Foam, Plastic, Cork & More
Custom die cutting services for gaskets, pads, dunnage, and prototypes, using rotary, flat bed, and steel rule die cutting for various materials, including die-cut foam and plastic parts.
At Solo Products, we specialize in custom die-cutting services built for industries that demand the highest quality and quick turnarounds. We produce die-cut parts and custom components from raw materials like foam, plastic, cork, and felt, shaped to your exact dimensions. From low-volume prototypes to large-format production runs, our team delivers precise die-cut gaskets, pads, and dunnage tailored for specific applications.
Industries We Serve
- Automotive – Vibration pads, BSR tape, interior seals, and noise-dampening components
- Food & Agriculture – FDA-grade die-cut inserts for safe, efficient transport
- Medical – Sterile packaging, cushioning, and sanitary seals
- Military & Defense – Mil-Spec gaskets and parts with CAGE code certification
- Distribution & Logistics – Dunnage, trays, and inserts for efficient facility workflows
As a trusted Midwest leader with over 24 years of experience and a U.S. Department of Defense and Defense Logistics Agency (DLA) Commercial and Government Entity (CAGE) Code 5JG25, Solo Products serves industries that demand reliability, quality, and quick turnarounds. From small custom projects to large-scale industrial production, Solo Products ensures efficiency without compromising precision.
Military Specifications We Support
Our military-grade materials meet ASTM and federal standards to support defense and aerospace requirements.
| Category | Spec | Additional Spec |
| Felt – Military | ASTM-D-2475 | C-F-206 |
| Foam Vinyl Nitrile | ASTM-D-1056 | Multiple Versions |
| Foam Polyethylene | A-A-59135 | A-A-59136 |
Die Cutting Capabilities by Material
We specialize in converting various materials, including non-metallic materials like foam, cork, and engineered plastics, into precision die-cut parts. Whether you need lightweight plastic films, adhesive tapes, or rubber materials, we turn raw materials into precision-cut components that meet specific shapes, thicknesses, and industrial tolerances.
| Material Type | Applications Include |
|---|---|
| PE Foam / EVA | Cushioning, anti-static protection, reusable dunnage |
| Felt | BSR tape, vibration pads, sound damping |
| Cork | Eco-friendly gaskets, insulation, protective inserts |
| Plastic / UHMW | Durable packaging liners, chute linings, plastic films |
| Corrugated Plastic | Lightweight reusable dunnage and container inserts |
👉 Explore individual services:
Cutting Methods & Advanced Capabilities
Our cutting methods include rotary and flat bed systems and steel rule die cutting for thicker or rigid substrates. These allow us to cut intricate designs accurately, custom dies, and specific shapes, ideal for low-volume orders or industrial-scale production.
- Flatbed & Steel Rule Die Cutting – Ideal for thicker materials and larger part formats, delivering consistent cuts and tight tolerances.
- Rotary Die Cutting – Efficient for high-volume orders, particularly for repetitive shapes and long runs.
- Adhesive Backing & Laminated Material – We work with PSA-backed and multi-layered components, offering flexibility for sealing, insulation, or mounting needs.
- Custom Cutting Equipment – From prototyping to short runs, our die-cutting systems accommodate different materials and shapes with extreme precision.
- Thickness Options – A wide selection of densities and material gauges ensures performance and durability based on your application.
Common Die-Cut Parts
Our die-cut parts are used across industries for high-volume or low-volume runs. We specialize in cut pieces built to custom designs, including die-cut foam pads, gaskets, and inserts. Whether you’re working with sensitive raw materials or need cylindrical die features, our solutions are tailored for your application.
- BSR Pads – Reduce buzz, squeak and rattle in auto interiors
- Gaskets & Seals – Precision-fit components for equipment and enclosures
- Reusable Dunnage – Custom inserts for returnable packaging systems
- Medical Components – Die-cut plastics and foams for hygienic applications
- Protective Liners & Inserts – Protect fragile goods during transport
Fast Turnaround, Trusted Quality
Unlike vendors with long lead times or unreliable stock, Solo Products keeps materials in stock and offers fulfillment in as little as 24 hours. Our in-house capabilities ensure accuracy, speed, and consistent quality, whether you need one prototype or 10,000 precision-cut parts.
Our Die Cutting Services
Plastic Die Cutting Services
Custom-Cut Plastic Components for Industrial and Commercial Use
Plastic materials are essential across industries for their strength, versatility, and durability. We offer precision die-cutting for materials like UHMW and durable engineered plastic, delivering consistent, high-quality results, whether you’re producing parts for automotive systems or durable industrial packaging.
Use Cases:
- BSR Anti-Vibration Pads – Custom-cut pads designed to reduce buzz, squeak, and rattle in automotive applications.
- Gaskets, Seals, and Washers – Custom precision parts for automotive, medical, and industrial use.
- Custom Packaging Inserts – Durable and reusable inserts for transport, including returnable dunnage.
- Medical Equipment Components – Die-cut plastic parts designed for hygiene, reliability, and performance.
- Conveyor Chutes and Liners (UHMW) – High-wear, low-friction plastic components ideal for industrial conveyor systems.
Discover More About Our Plastic Die Cutting Services
Foam Die Cutting Services
Custom Foam Solutions for Cushioning, Sealing, and Protection
We specialize in die-cutting PE foam, anti-static foam, and high-density varieties, ensuring durable cushioning, insulation, and vibration control solutions.
Use Cases:
- Protective Packaging and Cushioning – Custom foam inserts to safeguard delicate products.
- Adhesive-Backed Gaskets and Seals – For automotive and industrial sealing needs.
- Foam Tape and Weather Strips – Custom solutions for sealing and insulation.
- Custom Foam Inserts – Designed for returnable dunnage and delicate product storage.
Discover More About Our Foam Die Cutting Services
Felt Die Cutting Services
Custom-Cut Felt Solutions for Industrial and Automotive Applications
Felt is prized for its durability, flexibility, and sound-absorbing properties, making it ideal for cushioning, lining, and vibration damping. Our adhesive-backed, precision-cut felt components, like felt tape and BSR Tape, deliver consistent performance and easy application in demanding environments.
We also meet the Mil-C-F-206 specification, ensuring the quality and consistency required for government and military-grade felt applications.
Use Cases:
- Adhesive-Backed Felts – Ideal for automotive and industrial use, offering protective and functional padding.
- BSR Tape (Buzz, Squeak, and Rattle Reduction) – Designed to reduce vibration noise in automotive interiors.
- Vibration and Noise Dampening – Minimize sound and mechanical vibrations in machinery and vehicles.
- Protective Padding and Spacers – Cushion delicate parts or high-traffic contact points.
Find out how our Felt Die Cutting Services can streamline your production.
Corrugated Plastic Die Cutting Services
Durable Corrugated Plastic and Con-Pearl® Dunnage Solutions for Efficient Transport
Our corrugated plastic die-cutting services are built to protect, separate, and organize high-value parts during transport. Using plastic corrugated materials, we create durable, reusable dunnage solutions that meet the high demands of automotive, industrial, and e-commerce environments.
Con-Pearl® components and liners are a growing part of our offering, and we’re proud to support the future of sustainable, customizable dunnage with this innovative material. Whether you’re looking to reduce damage, increase efficiency, or streamline your material handling systems, Solo Products has you covered.
Use Cases:
- Protective Packaging for Automotive Components – Corrugated plastic partitions, trays, and separators made to fit your parts and containers.
- Custom Inserts and Trays – Designed to organize, protect, and increase efficiency in returnable container systems.
- Reusable Corrugated Plastic Dunnage – Durable, lightweight, and moisture-resistant solutions for multi-trip logistics.
- Con-Pearl® Layer Pads & Liners – Strong, lightweight sheets for palletizing and interior part protection.
Discover more about our Corrugated Plastic Die Cutting Services.
Cork Die Cutting Services
Custom-Cut Cork Solutions for Industrial, Packaging, and Insulation Needs
Cork is an eco-friendly, versatile material used in protective padding, insulation, and packaging. Our precision die-cut cork solutions are tailored for durability, moisture resistance, and easy application.
Learn more about sustainable cork harvesting and why it’s a leading choice for environmentally responsible manufacturing.
Use Cases:
- Protective Padding – For furniture, fragile items, and packaging inserts.
- Insulation Layers – Ideal for soundproofing, vibration damping, and thermal insulation.
- Custom Gaskets – Durable cork gaskets for industrial applications.
- Backing Materials – Perfect for coasters, trivets, and bulletin boards.
We offer custom thickness options and adhesive-backed cork materials for easy, eco-friendly solutions tailored to your needs.
Explore more about our Cork Die Cutting Services.
Why Choose Solo Products?
- Over 20 Years of Experience in die cutting and custom converting
- CAGE Certified (5JG25) for government and military compliance
- Stocked Materials for foam, cork, plastic, felt, and more
- 24-Hour Turnaround on many standard jobs
- Dedicated Support for complex and custom needs
Proudly Serving the Midwest and Beyond
At Solo Products, Inc. we proudly serve customers across the Midwest and neighboring regions, delivering precision die-cutting services with fast lead times and exceptional quality.
We serve businesses in the following states:
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Frequently Asked Questions
What is die cutting and how does it work?
Die cutting is a precision manufacturing process that cuts custom shapes from materials like foam, felt, plastic, rubber, etc. At Solo Products, we use flatbed and rotary die cutting machines, which we think of as high-powered industrial cookie cutters. Each “die” is engineered to match your exact design, ensuring consistency at scale.
Flatbed die cutting is ideal for thick or rigid materials, while rotary die cutting is perfect for roll-to-roll production, such as adhesive-backed parts or high-volume label runs.
What materials can Solo Products die cut?
We specialize in die cutting a wide range of materials, including:
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Foam (PU, PE, and more)
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Felt (including Mil Spec F-55 and PSA-backed options)
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UHMW and other engineered plastics
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Rubber, cork, fabric, foil, and adhesives
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Buzz, Squeak, and Rattle (BSR) materials for automotive NVH control
With over 24 years of experience, we serve industries like automotive OEM, defense, manufacturing, and distribution, delivering precision parts at competitive costs.
Can Solo Products die-cut plastic?
Yes — plastic die cutting is one of our core capabilities. We work with materials such as UHMW, HDPE, and other durable plastics to create precision parts for automotive, medical, packaging, and industrial use. Whether you need prototypes or full-scale production runs, we’ll tailor the right approach for your application.
How does Solo handle die cutting for foam materials?
Our team is highly experienced in converting a variety of foams, from thin PU foam strips to thick vinyl nitrile sponge or PE foam. To meet your project needs, we offer flatbed die cutting, traveling head presses, roll slitting, and laminating services. We also provide anti-static foams, high-density options, and CNC routing for more complex designs.
What role does CNC routing play in the die cutting process?
CNC routers give us the flexibility to produce high-precision parts without the need for traditional tooling. With tolerances as tight as ±0.03″, we can handle complex shapes, short runs, and fast turnarounds—while minimizing material waste and cost. This is ideal for prototypes, dense materials like UHMW, or when design iterations are required.
What is material converting, and why choose a specialist?
Material converting transforms raw sheets, rolls, or blocks into finished parts using cutting, laminating, slitting, or shaping processes. A skilled converting partner like Solo Products helps you reduce lead times, lower labor costs, and improve part quality.
We offer full-service converting from roll slitting to digital tool-free cutting, and bring decades of experience in the automotive, defense, and industrial sectors.
Why choose Solo Products for die cutting?
With over 24 years in the industry, Solo Products is a trusted partner for OEMs, defense contractors, and industrial manufacturers. We’re a DLA-approved supplier with CAGE code: 5JG25, and proudly serve the Midwest and beyond. Our facility houses advanced rotary presses, hydraulic flatbed cutters, CNC routers, and lamination lines, allowing us to deliver precision, speed, and scalability.
From prototype to production, Solo Products ensures quality, safety, and consistency every step of the way.
What’s the minimum and maximum production volume you can handle?
Whether you need one custom die prototype or 100,000 parts, we scale production quickly and cost-effectively without compromising high-speed turnaround or quality.
Not sure which process fits your needs?
Learn the key differences between CNC machining and die cutting.