PET film cutting

Custom-Cut PET Films in Standard or Made-to-Measure Formats

The term PET film cutting refers to cutting films made from polyethylene terephthalate (PET) into common standard formats or into shapes requested by customers. PET film cuttings produced in this way are further processed into products or packaging in a wide range of industries.

Industrial and commercial applications—especially in technical fields such as electrical engineering, mechanical engineering, medical technology, or the automotive sector—are complemented by the large packaging industry, where a significant share of PET film cuttings is used.

A smaller niche is found in the graphic and decorative sector, where PET film cuttings serve as the basis for prints, wall decorations, or even artworks.

Basic Information About the Material PET

PET is a thermoplastic material characterized by high strength, good dimensional stability, and very good resistance to water and many chemicals. PET films can be produced as transparent or translucent materials. Colored or opaque PET films are also possible.

Typical properties of PET include high tensile and tear strength, good barrier performance against gases and moisture, and high temperature resistance. Additional advantages of PET are its physiological safety and a well-established recycling loop. For these reasons, PET is widely used especially in the food and pharmaceutical sectors.

There are different types of PET films, all of which can be further processed through PET film cutting:

• Amorphous PET films (A-PET) have no crystalline structure and are produced by rapid cooling of the extruded material. Their clarity and flexibility make them the film of choice for certain applications.
• Semi-crystalline PET (C-PET) is produced through a normal cooling process.
• If heat is applied again immediately after production and the film is stretched simultaneously in two directions, biaxially oriented PET (BO-PET) is created with a more stable crystalline structure. This process improves the mechanical and chemical/physical properties of the films.

PET Film Cutting and the Distinction from Thermoforming

A PET film cutting refers to a piece of film that is cut to precise dimensions from a larger PET film web or, in the case of thicker material, from a PET sheet. The PET film cutting is exactly matched to its intended application.

PET film cuttings can be produced in rectangular, square, round, or fully customized shapes according to customer specifications. For further processing, it is important that very tight dimensional tolerances are maintained during PET film cutting.

Film cutting must be distinguished from deep-drawn or thermoformed PET parts, where the material is additionally shaped into a three-dimensional form. In such cases, parts may be further processed from a PET film cutting, or molded parts are produced directly from a film web and then cut out.

In pure PET film cutting, the film remains flat. However, openings, slots, or complex contours can still be integrated into a PET film cutting.

The Term PET Film Cutting Refers to Various Manufacturing Methods

PET film cutting can be carried out using different processes. The choice of method depends on factors such as production quantity, the complexity of the required shapes, and the precision requirements of the PET film cutting. Common methods include:

• Punching Particularly suitable for high volumes and contours of simple to medium complexity. Punching machines allow PET film cutting at high process speeds and enable the production of many identical parts.
• Laser Cutting Offers high flexibility and precision. Laser cutting is mainly used for delicate contours or small production runs.
• CNC Milling CNC milling is used for processing thicker PET films. Complex geometries can be produced with high precision.
• Shear Cutting In shear cutting, PET film cutting is performed using two blades moving against each other, similar to scissors. Machine-based shear cutting is suitable for simple cuttings and is often used for prototypes. This method is only suitable when there are low requirements for edge quality.
• Plotter Cutting In PET film cutting with a cutting plotter, a computer-controlled blade is guided through the material to be cut. Plotters work very accurately and can produce complex shapes. However, they are not suitable for large-scale production.

The required quality of the cut edges is a key factor in determining which method can be used. The necessary production volume determines which process is most cost-effective. Punching, for example, is a very economical method for PET film cutting, but it only becomes worthwhile above certain quantities because a dedicated tool must be manufactured.

Application Areas for PET Film Cuttings

PET film cuttings are either carried out directly by the film manufacturer, or users purchase PET film in roll or sheet form and perform the cutting process themselves before the actual production step. PET film cuttings are needed in numerous industries.

In the packaging industry, they are used as viewing windows in cardboard packaging, blister covers, or separating layers between products.

In electrical engineering, they are used for electrical insulation, as spacers or protective covers, and in the manufacture of many products such as displays, keyboards, or screens.

In mechanical and plant engineering, PET cuttings are used as protective films, sliding layers, or covers.

In medical technology, PET film cuttings are applied, for example, as sterile packaging components or as carrier materials for diagnostic systems.

PET film cuttings are also used in the graphic sector, for example for displays, signs, or printed materials.

Advantages and Properties of PET Film Cuttings

• Precise pre-cutting reduces assembly times and minimizes material waste.
• High dimensional accuracy ensures consistent quality in further processing.
• PET cuttings can be easily printed, coated, or laminated.
• PET is resistant to many chemicals, oils, and fats.
• PET is a highly durable material with good aging performance.
• High transparency allows use in visual applications, while matte or textured surfaces can reduce glare, and colored PET film cuttings provide visual and light protection.
• Depending on the base material (A-PET, C-PET, or BO-PET) and surface treatment, PET films can be used in various fields with different requirements.

Quality Characteristics for PET Film Cuttings

Important quality criteria for PET film cuttings include dimensional accuracy, good flatness, high edge quality, and the required surface condition. Depending on the application, film customers may demand very tight tolerances in the range of tenths or even hundredths of a millimeter.

During PET film cutting, no scratches or inclusions may occur in the material, and internal stresses must also be avoided, as such deviations can impair performance during further processing.

In sensitive fields of application, such as the food industry or medical technology, PET film cuttings must meet very high standards of cleanliness and hygiene. Traceability and compliance with specific standards must be ensured and certified. Manufacturing processes must be standardized and clearly documented.