Rotary Die-Cut Component Design & Prototyping

Engineering precision components from concept through production-ready design.

Little Creek Labs, Inc. specializes in the design, engineering, and prototyping of components intended for rotary die-cut manufacturing. We help customers develop films, adhesives, foams, liners, gaskets, seals, and multilayer constructions for medical and industrial products. Our particular expertise is in skin-contacting medical products and components.

Designed for Rotary Die-Cut Manufacturing

Rotary die cutting can provide efficient, repeatable production for many flexible components—but successful production begins with the component design. Little Creek Labs develops components with their eventual manufacturing process in mind. We consider material characteristics, geometry, tolerances, adhesive systems, layer construction, registration, tooling, and production requirements during development.

We then work with qualified manufacturing partners to transition validated designs into production.

From Concept to Production

1 — Design
Develop the component around its functional requirements and intended application.

2 — Prototype
Produce prototypes to evaluate geometry, materials, construction, and interfaces.

3 — Refine
Incorporate prototype results into the component design.

4 — DFM
Optimize the design for rotary die-cut production and other manufacturing requirements.

5 — Production Transition
Work with an appropriate manufacturing partner to move the validated design into production.

Skin-Contacting Medical Components

Little Creek Labs has particular expertise in developing components used in medical products designed to interface with the skin.These products may incorporate:

• Pressure-sensitive adhesives
• Films
• Foams
• Liners
• Flexible substrates
• Multilayer constructions
• Precision-cut components

Our development process considers the complete component construction and how it will ultimately be manufactured.

What We Develop

• Adhesive Components
  Precision adhesive and PSA constructions designed for medical and industrial applications.
• Film Components
  Engineered films and flexible material constructions developed for precision converting.
• Foam Components
  Die-cut foam components, cushioning layers, and flexible constructions.
• Multilayer Components
  Laminated and layered constructions requiring controlled alignment and registration.
• Gaskets & Seals
  Precision component designs for sealing and interface applications.
• Custom Flexible Components
  Specialized component designs developed around specific material, geometry, and manufacturing requirements.