Die-cut foam parts are components pressed from foam sheet with a steel-rule die — gaskets, seals, pads, spacers, separators and packaging inserts — in EPE, EVA, PU or cross-linked PE, plain or with pressure-sensitive adhesive. Balaji International makes the dies and the parts in Rajkot and supplies them across India in bulk or kitted.
Technical foam parts are the foam components that go into or around a product rather than just its box: the gasket under an enclosure lid, the pad behind a nameplate, the spacer between two PCBs, the anti-vibration foot under a compressor. They are small, numerous and tolerance-sensitive, and they are almost always die-cut.
We make the die, cut the part, apply the adhesive and pack to your count. Because the foam comes off our own extrusion line, thickness and density are specification decisions rather than stock constraints.
Supply specification
| Materials | EPE (18–35 kg/m³), EVA (60–120 kg/m³), PU (16–40 kg/m³), XLPE/IXPE, anti-static and conductive grades |
|---|---|
| Thickness | 0.8 mm to 50 mm in a single stroke; laminated above that |
| Outline tolerance | ±0.5 mm standard; ±0.3 mm on firm EVA and XLPE |
| Adhesive options | Acrylic PSA (general), rubber PSA (high tack), double-sided, with easy-peel liner |
| Supply formats | Loose in bulk, on liner rolls (kiss-cut), or kitted per assembly |
| Die types | Flatbed steel-rule dies; rotary dies for high-volume thin parts |
| Input accepted | DXF/DWG, PDF, physical sample, or the mating part |
Which foam for which technical part
Gaskets and seals need a closed-cell foam that recovers after compression and does not take up water: cross-linked PE or firm EVA, typically 3–6 mm, compressed 25–40% in service. Open-cell PU is the wrong material here — it wicks moisture and takes a permanent set.
Pads, spacers and anti-rattle parts are usually EVA or EPE, chosen by how much load they carry. Anti-vibration feet under motors and compressors want a firm, dense grade — EVA at 100–120 kg/m³ or a rubberised foam — so that they isolate rather than bottom out. Packaging inserts and separators are almost always EPE because it is the lightest material that survives repeat impact.
How die-cutting works, and where its limits are
A steel-rule die is a plywood or metal base with hardened steel blade set into it along the part outline. The press drives the die through the foam sheet in one stroke, so every part is identical and cycle time is seconds. Nesting parts closely across the sheet is where material yield — and therefore cost — is decided.
The limits are depth and geometry. Above about 50 mm the blade deflects and edge accuracy falls off; stepped floors, deep pockets and undercuts cannot be die-cut at all. Those parts are CNC-routed, and we will say so at quotation rather than force a die to do a job it cannot.
Adhesive backing — the detail that decides whether the part works
Most technical foam parts are adhesive-backed, and the adhesive is chosen by the surface and the service temperature, not by the foam. Acrylic PSA is the general-purpose choice: good on metal and painted surfaces, stable in Indian warehouse heat. Rubber-based PSA has higher initial tack for low-energy plastics but ages faster.
Kiss-cutting — cutting through the foam and adhesive but not the release liner — leaves parts on a roll that an operator peels off one at a time. For line-side supply it is faster and cleaner than loose parts in a bag, and it is how most electronics and automotive customers take delivery.
Industries we supply
Electronics & appliances
PCB spacers, battery pads, speaker gaskets and conductive separators cut from anti-static or conductive foam.
Electrical enclosures & panels
Closed-cell XLPE and EVA lid gaskets that hold IP-rated compression over years of service.
Automotive & two-wheeler
Anti-rattle pads, trim spacers and dust seals supplied on rolls or in kitted counts to the line.
Packaging inserts
Die-cut EPE and EVA layers, separators and cavity inserts at volume, nested for material yield.
Dispatch & lead times
| Die from approved drawing | 3–5 working days |
|---|---|
| First-article sample | With the die, for approval before the run |
| Production run | 5–10 days depending on quantity |
| Gujarat | 1–2 days from dispatch |
| Rest of India | 2–6 days from dispatch |
Common specifications
Common questions
What are technical foam die-cut parts?
Foam components that perform a function on the product itself — gaskets, seals, pads, spacers, separators, anti-vibration feet — rather than just cushioning it in transit. They are pressed from foam sheet with a steel-rule die, usually with adhesive on one face, and supplied loose, on liner rolls or kitted.
What tolerance do you hold on die-cut foam parts?
±0.5 mm on the outline is standard, and ±0.3 mm is achievable on firm closed-cell foams such as EVA and XLPE. Soft PU and thick EPE are looser because the material compresses under the blade. Tell us which dimension is functional and we will control that one.
Can you supply die-cut foam with adhesive backing?
Yes — acrylic or rubber-based pressure-sensitive adhesive, single or double sided, with an easy-peel liner. Kiss-cut parts on liner rolls are the usual format for line-side use. We will recommend the adhesive from the surface it bonds to and the temperature it sees.
What is the minimum order for die-cut foam parts?
The die is a fixed cost recovered across the run, so the practical minimum is where that cost per part becomes acceptable — usually a few hundred pieces for a simple outline. Below that we CNC-route with no tooling and you approve a physical part before deciding on a die.
Do you make anti-static or conductive die-cut parts?
Yes. Pink anti-static EPE and PU at 10⁹–10¹¹ Ω/sq for enclosed assemblies, and black carbon-loaded conductive foam below 10⁴ Ω/sq for bare boards and exposed pins. The grade follows what the part touches, and we will specify it from that.
Send us your specification
Product weight, dimensions, monthly volume and where it ships. We quote within one working day and will tell you if a cheaper specification would do the same job.
Prefer to talk?
Product weight, dimensions, monthly volume and where it ships. We quote within one working day and will tell you if a cheaper specification would do the same job.