Plug Insulator

Problem

The adhesive-backed plug insulator shown here is manufactured from thin gauge ITW Formex® GK-10BK and 3M 467MP transfer tape. At ESPE Manufacturing Co., Inc., our challenge was to engineer a production strategy that was both efficient and cost effective in order to meet the client’s budgetary requirements and tight time constraints.

Solution

By combining the powerful features of laser cutting equipment with our years of experience cutting a wide variety of flexible substrates, we developed a high-speed, low-cost solution. Our production methodology involved a sequence of steps that included laser cutting, scoring, perforating, and kiss cutting. We used a part layout that enabled us to achieve a high material yield and eliminate costly scrap. For the kiss cutting, we programmed our laser cutter with the appropriate power and speed to ensure the beam only cut through the Formex GK-10BK layer and did not penetrate the adhesive backing, which allowed the plug insulator to be easily peeled off. Continuous monitoring of our production processes combined with in-process and final inspections ensured the parts conformed to the customer specification.

Results

The finished product features dimensions of 3.40″ in length x 1.825″ in width. Produced to within ±0.005″ tolerances, it satisfied all of the customer’s requirements regarding quality and pricing. Since our production operations enabled fast throughput, we were able to fulfill repeat orders within five to ten days, even for large production volumes.

For more information about this project, or the processes used to manufacture it, see the table below or contact us directly.