Capabilities
Production Processes
Flat-bed, auto-feeding die cutting (presses up to 84” wide)
Our primary production capability. Flatbed die cutting delivers precise, repeatable parts across a wide range of materials and part geometries — from 1×2mm detail components up to the full 84" press width. Auto-feeding systems support consistent, high-volume output with minimal material waste. Well-suited for automotive NVH parts, large-format insulation panels, and everything in between.
Clamshell (book) die cutting
Clamshell die cutting is ideal for thicker or more rigid materials that benefit from full, even press contact. This process is commonly used for foam gaskets, cork seals, and multi-layer laminated assemblies where flatbed throughput isn't required.
Knife cutting
Knife cutting is a flexible, tooling-free option for prototypes, short runs, and materials that require careful handling. It is frequently used during program development before committing to hard tooling, and for specialty configurations not suited to die cutting.
Sheeting
We sheet roll-stock materials into flat sheets of specified dimensions — a critical preparation step for many die cutting and lamination programs. Sheeting services support in-house production and customer-managed material programs.
Laminating (up to 60” wide)
Roylco’s lamination capability bonds two or more materials together — such as foam to barrier film, or felt to PSA — to create multi-layer composites engineered for specific acoustic, thermal, or assembly requirements. Lamination is performed up to 60” wide.
Heat-sealing
Heat-sealing bonds compatible materials without adhesives, using controlled temperature and pressure to create clean, durable bonds. This process is used for specific nonwoven and film combinations where PSA is not appropriate.
Pressure Sensitive Tapes
We apply PSA backing to die-cut parts for peel-and-stick installation on assembly lines. PSA-backed parts can be supplied on liners in die-cut, kiss-cut, or slit tape configurations, including single- and double-sided options.
Assemblies
For programs requiring multiple components or materials, Roylco can assemble die-cut parts into finished sub-assemblies, reducing handling steps and simplifying receipt for the customer.
Packaging
We package finished parts to customer specifications — loose, bagged, labeled, or kitted — for direct delivery to production lines or distribution centers.
Cost-Effective Support Processes
Roylco creates and maintains cutting dies in-house, reducing lead times and tooling costs compared to outsourcing. In-house tooling capability means faster iteration during prototype development and reliable maintenance of your tooling inventory for ongoing programs.
Our quick-turn prototyping service delivers sample parts — often within days — so engineering and procurement teams can validate designs before committing to production tooling and volume. No minimum order quantities on prototype runs.
Worldwide freight
We ship domestically and internationally, supporting customers with multi-location manufacturing operations and global supply chains.
Questions? Just ask!
