When choosing the best method for shaping and finishing your foam inserts, understanding the difference between CNC and die cut foam can help you make the right decision. At PottertonPacs, we use both CNC routing and die cutting to produce accurate, high-quality foam inserts for all types of packaging. Each technique has its strengths depending on your design, order size, and budget.
Understanding the Two Cutting Methods
Both CNC routing and die cutting are professional cutting methods used to shape foam for packaging, cases, and protective inserts. The main difference lies in how the foam is cut. CNC routing uses a computer-controlled cutting tool, while die cutting relies on a pre-shaped metal die.
CNC routing offers flexibility and precision for detailed designs, while die cutting is ideal for high volume production runs that need speed and consistency. At PottertonPacs, we use both techniques to deliver custom foam inserts that are accurate, durable, and produced cost effectively.
CNC Routing Explained
CNC routing (Computer Numerical Control routing) is a modern method that uses a digital file to guide a sharp cutting tool across a sheet of foam. The machine follows the design exactly, cutting out shapes, slots, and edges with incredible accuracy.
This process is perfect for prototypes, small production runs, or projects that require detailed work. It allows our team to make small adjustments to your design without the need to create new equipment, which helps reduce costs for unique or low-quantity projects.
CNC routing is also ideal for layered foam inserts or designs that include different depths within one layout. Because the router can move up and down in very small steps, it provides precise control over every cut. This makes it excellent for display cases, demonstration kits, or packaging that needs a professional finish.
At PottertonPacs, our advanced routers can cut a wide range of foams with consistent accuracy. Whether you need protective inserts, technical layouts, or presentation trays, CNC routing gives you freedom to customise your design exactly as you want.
Die Cutting Explained
Die cutting is a traditional but extremely efficient cutting method that uses a custom-made steel die to stamp shapes into foam. The die is designed to match the exact outline of your product or layout. Once created, it can be used again and again, making it perfect for high volume production.
Because the process is mechanical, die cutting is faster than CNC routing. It can produce hundreds or thousands of identical foam parts in a short time. This is ideal for packaging lines, manufacturing kits, or any business that needs bulk quantities cost effectively.
The die itself works like a cookie cutter, pressing into the foam to create clean edges and uniform shapes. Although it does not allow as much variation as CNC routing, it offers outstanding repeatability and value for large orders.
Our team at PottertonPacs designs and manages the complete die cutting process in-house, ensuring that each run meets the same high standards. We store your dies for future use, making re-orders quick and simple.
Choosing Between CNC Routing and Die Cutting
The choice between CNC routing and die cutting depends on the type of project and your specific needs. Here are some key factors to consider:
Quantity:
For small or one-off projects, CNC routing is more practical. For high volume orders, die cutting offers faster production and lower unit cost.
Complexity:
If your design involves fine details, multiple depths, or intricate patterns, CNC routing gives better results. Die cutting is best for simple, repeated shapes.
Speed and Budget:
CNC routing can be slower but is more flexible and ideal for short runs. Die cutting is faster and more economical when you need large quantities cost effectively.
Material Type:
Both cutting methods work well with foams such as polyethylene and polyurethane. However, certain densities may perform better with one process over the other. Our experts can guide you based on your material choice.
How PottertonPacs Uses Both Methods
We often combine both cutting methods within one project. For example, CNC routing can be used to create a prototype for approval, while die cutting can then produce the full batch for delivery. This approach gives you the best of both worlds: accuracy and speed.
Our goal is to help clients choose the most efficient and cost effective method for their needs. We take into account your foam type, product shape, and order size to recommend the best process.
Advantages of Working with PottertonPacs
PottertonPacs has years of experience using both CNC routing and die cutting to produce precision custom foam inserts. We work with businesses across manufacturing, engineering, and sales sectors to deliver packaging that looks professional and performs perfectly.
Every project begins with a design consultation, where we review your items and recommend the most suitable foam and cutting method. We then produce your inserts with attention to detail, ensuring that each piece fits perfectly within your case or packaging.
Get Expert Advice
If you are unsure which method is right for you, please contact PottertonPacs. Our experienced team will explain the difference between CNC and die cut foam in detail and help you find the process that meets your needs.
Whether you need one prototype or a high volume production run, we will provide custom foam inserts that are accurate, consistent, and made cost effectively. For reliable results and long-lasting quality, trust PottertonPacs to handle all your foam cutting requirements.
