The term Through-Cut describes a cutting process in which all material layers are completely severed. Unlike Kiss-Cut, where the liner remains intact, in Through-Cut the die-cut part and the liner are separated from one another.
In short: Through-Cut produces a completely die-cut part that can be removed individually or processed directly. This process is used wherever insulation parts, seals, labels or film blanks are required as free-standing individual parts.
Working Principle and Processes
In Through-Cut, the material is completely separated by a tool or laser. Typical processes are:
- Rotary die cutting: continuous full-depth cutting in roll processes with die cylinders.
- Flatbed die cutting: stroke motion with die forms, suitable for thicker materials and medium series.
- Laser cutting: non-contact full-depth cutting for complex geometries or small quantities.
- Digital plotter cutting: knife or routing tools for prototypes, one-offs or flexible orders.
Materials for Through-Cut
The process is suitable for many technical substrates required as individual parts:
- Electrical insulation films: PET (HOSTAPHAN, Mylar), polyimide (Kapton), PVC, polypropylene.
- Aramid paper (Nomex): for coil, motor and transformer insulation.
- Multilayer laminates: DMD, NMN, PET and Kapton laminates.
- Adhesive tapes: acrylate and silicone adhesives on PET or polyimide carriers.
- Nonwovens and foams: for seals, spacers or damping elements.
- Labels and markings: nameplates, serial number labels, ESD labels.
Differences from Kiss-Cut
- Through-Cut (full cut): all layers severed, part and liner separated, parts available individually.
- Kiss-Cut (half cut): facestock and adhesive separated, liner remains intact, parts remain on the carrier until removal.
Takeaway: Kiss-Cut for assembly-friendliness on roll material, Through-Cut for free- standing parts.
Quality Characteristics and Tolerances
A clean Through-Cut is characterized by:
- Burr-free cut edges without tears.
- Dimensional accuracy according to DIN ISO 2768.
- No thermal damage to the material during laser processing.
- Low particle generation, important for insulation parts in electric motors or cleanroom applications.
- Reproducible edge quality even with fibrous materials (Nomex, nonwovens).
Inspection is performed optically (inline camera), mechanically (cutting force) and electrically (for insulation films: dielectric strength).
Applications
- Electrical industry: individual parts from Kapton, Nomex or polyester films as interlayers, insulation films or coil parts.
- Automotive: seals, adhesive pads, EMI shielding, thermal pads.
- Electronics manufacturing: labels, serial number labels, masking for coating.
- Mechanical engineering: shim plates, sliding and damping elements.
- Contract slitting: manufacture of custom geometries for customers from roll or sheet material.
Advantages and Challenges
Advantages
- Parts are immediately available as free-standing units.
- No liner residues or matrix required.
- Universally combinable with die cutting, laser or plotters.
- Clean edges with proper process management.
Challenges
- Higher handling costs for individual parts (no liner as carrier).
- More elaborate packaging and logistics.
- Tool wear with thick or abrasive materials.
- Risk of burr or particle formation in unclean processes.
GOBA Takeaway
Through-Cut is the standard process for free-standing insulation parts, seals and film blanks. While Kiss-Cut offers assembly-friendliness through the carrier material, Through-Cut delivers the finished individual part. For the electrical industry this means: depending on the assembly process, the decision is made whether parts are supplied on the liner (Kiss-Cut) or as free-standing stamped parts (Through-Cut). Precise tools, clean cutting parameters and material expertise ensure dimensional accuracy and quality.