PRODUCT FEATURES
Choosing the correct rubber hardness—whether for ejection rubber on the die board or the counter pad/anvil beneath—is critical in flat die making. The right balance ensures clean cuts, longer blade life, and smooth material ejection. For factories striving for efficiency and consistent results, fine‑tuning this selection is essential.
At YITAI Die Making Supply, with 40+ years of Taiwanese die‑making expertise, 33 specialized factories worldwide, and a full range of precision machinery and consumables, we see rubber hardness selection as one of the most overlooked but most influential factors in die performance.
Cut Quality: Prevents tearing, crushing, or incomplete cuts.
Blade Protection: Extends tool life by reducing premature dulling.
Material Ejection: Reliable rebound ensures waste-free production.
Factory Efficiency: Minimizes downtime from inconsistent cutting or pad replacement.
| Application | Shore A Hardness | Why It Works |
|---|---|---|
| Pressure-sensitive labels (kiss-cut) | 80–95 | Hard enough to protect silicone liner. |
| Paperboard / cartons | 70–85 | Balanced hardness for clean edges & ejection. |
| Thin films (PET, PVC) | 75–85 | Stable support, prevents wrinkling. |
| Foam or rubber sheets | 50–70 | Soft to absorb compression without deforming. |
| Textiles / leather | 60–75 | Gentle hardness avoids visible marking. |
| Metal foils | 85–95 | High hardness resists blade shock. |
Rule of Thumb: Softer rubber = smoother ejection, harder rubber = sharper precision.
| Material Thickness | Shore A Range | Rubber Height |
|---|---|---|
| ≤0.2 mm (films, foils) | 80–90 | 2–3 mm |
| 0.2–0.6 mm (labels, papers) | 75–85 | 3–4 mm |
| 0.6–1.5 mm (cartons) | 70–80 | 4–6 mm |
| 1.5–3.0 mm (boards, textiles) | 60–75 | 6–8 mm |
| >3.0 mm (foam, dense substrates) | 50–70 | 8 mm+ |
Blade penetration should extend 0.5–1.5 mm past material thickness.
While ejection rubber is Shore A, the anvil pad requires much higher hardness (Shore D).
Kiss-cutting: Steel counter plates.
Through-cutting: Hard plastics like UHMW‑PE, nylon, polyurethane.
Guideline: The anvil must always be harder than the ejection rubber to maintain accuracy.
Setback: 0.5–1.0 mm from rule for through‑cuts; 1–2 mm for kiss‑cut.
Height tolerance: Keep within ±0.1–0.2 mm for consistent depth.
Profiles: Beveled/scalloped rubber for curves and tight radii.
Vent gaps: Allow air release to prevent sticking of small cut pieces.
| Issue | Likely Cause | Solution |
|---|---|---|
| Incomplete cut | Rubber too hard or uneven height | Use softer grade, re‑level pad. |
| Blade dulling fast | Rubber too hard, abrasive material | Drop hardness, consider coated rule. |
| Poor ejection | Rubber too hard, low rebound | Switch to higher‑resilience PU. |
| Crush marks | Rubber too tall/hard | Lower height, use beveled profile. |
| Liner damage (kiss‑cut) | Rubber too soft or close | Increase hardness/setback. |
Polyurethane (50–95 A): Long‑lasting, industry standard.
Natural/Synthetic Rubber: Economical, shorter service life.
Composite Pads: Combine a hard base with softer top for precision + ejection.
For adhesive substrates, composites, or ultra‑thick stacks, suppliers can provide:
Multi‑layer ejection pads
Oil‑ and heat‑resistant compounds
Color‑coded hardness for easy identification
Send an inquiry right now, our sales will reply with the price within 12 hours.
