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Die-Cuts: Replacing Metal Fasteners and Liquid Adhesives

Die-Cuts: Replacing Metal Fasteners and Liquid Adhesives

Last updated Dec 21, 2023 | Published on Sep 6, 2017

When it comes to holding two materials together, die-cuts offer many advantages when compared to other fastening methods.

Mechanical fasteners and liquid adhesives have been used to fasten and hold two materials together for centuries. However, this does not mean that they are the best or most cost-effective option available. The traditional usage of hardware is being replaced by a superior alternative: die-cut adhesives. In this blog, we will help you understand how strong double-sided tapes and high bond adhesives can be and how they can save your manufacturing process time and money.

Two of the most common examples of die-cut adhesives are double-coated tapes and high bond adhesives. Both types of tapes are available from a variety of suppliers and are precision converted and die-cut by Boyd.

Problems with Mechanical Fasteners

Mechanical fasteners such as screws, nuts, bolts, and rivets, are often visible and distracting on a device and prevent it from having a smooth, sleek appearance.

Mechanical fasteners require drilled holes in your product. Holes made for these fasteners can accelerate corrosion and potentially decrease the life of the product. When fasteners are under stress or vibration, they can loosen or slide, exposing unattractive unpainted areas and hastens the corrosion process even further.

In addition, if the product is used outdoors and subject to rain or other forms of moisture, fastening holes can also cause leaking. Leaking can allow moisture and other unwanted materials to enter into your product and cause damage.

Problems with Liquid Adhesives

During the application process, liquid adhesives can be irritating to the eyes and skin and produce nauseous fumes. In environments like this, cumbersome respirators and gloves are often needed during the manufacturing process.

When applying two substrates together with a liquid adhesive, the bond line thickness can be inconsistent; this can weaken the strength of the bond and alter the true dimension of the part. Push out or “squeeze out” of adhesive can occur, which creates a mess and increases clean up time unnecessarily. Liquid adhesives also need time to dry, slowing the manufacturing process and causing bottlenecks. Lastly, equipment for dispensing liquid adhesives expensive and potentially cost prohibitive.

Solution: Die-Cut Adhesives

Boyd provides die-cut solutions that can replace mechanical fasteners and liquid adhesives in many scenarios. High bond and double-coated tapes are generally water-resistant and can provide solutions for gap-filling, bonding irregular surfaces, cushioning and dampening vibration, sealing, attaching and hanging lightweight objects, and providing long-term durable bonds. The viscoelastic properties of the adhesives can help to reduce stress, squeaks, rattles, and noise vibrations as well. These adhesives are a great fit for small electronic devices, metal skins, bonding decorative metals, and assembly of devices such as computers, tablets, and cell phones.

Assembly is quick and easy by peeling off release liners and attaching the two substrates together. These tapes are highly effective in hot, cold, and even humid conditions. Die-cut adhesives are UV resistant can maintain strength and withstand all outdoor conditions for up to 35 years.

Tapes can also be placed in areas where it’s difficult to utilize mechanical fasteners. An example includes the placement of a small cooling fan in an electrical device. It is easier and more efficient to use small die-cut pieces of tape to fasten the cooling fan in place instead of screws. The adhesive can also help dampen the noise from the fan.

Boyd is a preferred converter for a variety of adhesive suppliers. Contact us to discuss how die-cuts can replace your mechanical fasteners, in turn reducing your manufacturing costs, bonding issues, and improving the appearance of your product

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