Large format die-cut foam gasket solution | Case study | Melrose Nameplate & Label Co. | U.S. Manufacturing Solutions

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Large format die-cut foam gasket solution

A key customer of Melrose was looking for a large format foam gasket of 34” x 55” dimensions. They required a combination of closed-cell foam and high-bond adhesive to dampen inside a kiosk enclosure.

The challenge

Find a combination of foam gasket materials with matching performance properties. Determine which manufacturing processes require assembling and fabricating the parts, and finally, ensure that we can align the plan and resources to deliver to the client’s schedule.

The solution:

Melrose provided the customer with a large format die-cut solution meeting the requirements using the suitable material and manufacturing process.

Material:

Leveraging two key material supply partners, Melrose was able to source the needed performance foam and adhesive components.

Processing:

The Melrose team followed a combination of large-format lamination and digital fabrication to provide a manufacturing solution that could meet the requirements of the part.

Key elements:

Part size: 34” x 55”
Material: Closed cell .375” thick performance-engineered foam with .025” high-performance acrylic foam tape.
Fabrication: Large format lamination and digital fabrication to manufacture a part, nearly 3’ft by more than 4½’ft.

Result:

We provided a proper die-cut foam solution matching the performance criteria, and the manufacturing process ensured delivering the large gasket foam in time.

Why Melrose?

Our mission is to deliver timely solutions to our customers through key partnerships and our more than 80 years of manufacturing experience and expertise.

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