Die-cut non-woven and shoddy materials are a staple of automotive interior and underbody insulation programs. Roylco cuts non-wovens to precise tolerances for trunk liners, wheel well covers, door panels, and carpet underlayment. These materials offer excellent sound absorption and thermal insulation at a competitive cost. Available with PSA backing for simplified installation on assembly lines. We cut non-wovens from 1×2mm detail parts up to 84” wide, supporting both prototype and high-volume production programs.

Roylco is an experienced cutter of 3M Thinsulate acoustic and thermal insulation, with production capability across BMW TL, DBL, GMW, and Ford WSS/WSK specifications. Thinsulate is widely specified in automotive programs for door panels, headliners, and HVAC duct insulation due to its thin profile and strong NVH performance. We offer slit, laminated, and kiss-cut configurations with liner options for automated or manual assembly line placement. Quick-turn prototyping available for new program development.

Thermal ceramic materials are engineered for high-temperature insulation where standard foams and felts fall short. Roylco has hands-on experience cutting thermal ceramics for electric vehicle battery insulation, where precise fit and dimensional consistency are critical for thermal protection and cell separation. We also cut thermal ceramics for HVAC and industrial applications requiring extreme temperature resistance. Our flatbed presses deliver clean, accurate edges on these brittle materials.

Die-cut polyester nonwoven materials serve a wide range of automotive and industrial applications, including air filtration layers, duct insulation, and interior trim backing. Polyester offers a reliable balance of acoustic performance, dimensional stability, and cost. Roylco cuts polyester in complex geometries with consistent tolerances, and can laminate PSA backing for peel-and-stick installation. Compatible with high-volume production programs across automotive, HVAC, and packaging industries.

Industrial felt is one of Roylco's core materials. We cut felt daily for automotive anti-squeak (BSR) applications, furniture leg protection, HVAC gasketing, and decorative trim components. Our capability spans wool, synthetic, and blended felts across a wide range of thicknesses. PSA-backed felt tape configurations are available with or without liners. Roylco's felt parts are found in automotive door panels, center consoles, seat assemblies, and appliance interiors across multiple industries.

Roylco cuts a wide variety of open- and closed-cell foams for cushioning, sound insulation, gasketing, and thermal management applications. Foam die cutting is central to our automotive, furniture, packaging, and HVAC programs. We cut polyurethane, polyethylene, cross-linked PE, and specialty acoustic foams, including those meeting OEM specifications. Foam parts can be laminated, PSA-backed, or supplied on a liner for automated placement. Tolerances are held to +/-0.5mm on most foam programs.

EPDM rubber is a preferred material for weather seals, HVAC gaskets, vibration isolators, and outdoor-rated components. Roylco's flatbed presses cut EPDM cleanly in both solid and sponge grades, producing consistent parts for automotive and HVAC production programs. Common applications include door seals, air duct grommets, electrical enclosure gaskets, and vibration-dampening pads. PSA backing is available for direct-bond installation.

Polycarbonate is a rigid engineering plastic used in protective covers, electrical insulation, and structural reinforcement applications. Roylco cuts polycarbonate sheet to precise tolerances for industrial and specialty applications including protective guards, instrument panel components, and electronic housings. It is commonly specified where impact resistance and dimensional precision are required alongside low weight.

Cork's natural compressibility and chemical resistance make it well-suited for gaskets, seals, vibration dampeners, and underlayment. Roylco cuts cork composition and natural cork sheet for automotive, industrial, and architectural applications. Die-cut cork gaskets are common in engine compartment and HVAC applications, while cork underlayment and furniture pads represent strong non-automotive volume. Cork can be supplied with or without PSA backing.

Roylco cuts a broad range of plastic sheet and film materials including PET, polypropylene, ABS, and vinyl. Plastic die cuts are used for protective liners, structural inserts, electrical insulation, and packaging components. Our flatbed presses handle both thin film and rigid plastic sheet, maintaining tight dimensional tolerances across production runs. We support programs from prototype through high-volume production.

Die-cut mesh materials are used in filtration, ventilation, acoustic baffling, and composite reinforcement applications. Roylco cuts woven and nonwoven mesh in a variety of polymers and fiber types for HVAC filters, speaker grille inserts, and protective screens. Cutting mesh to precise dimensions requires sharp, well-maintained tooling — our in-house tooling capability ensures clean edges and consistent output.

Natural and synthetic rubber die cuts from Roylco serve gasketing, sealing, cushioning, and vibration-isolation applications across automotive, defense, HVAC, and industrial markets. We cut rubber across a wide range of durometers and thicknesses. Common applications include door and enclosure gaskets, anti-vibration mounts, and industrial seals. PSA backing is available for adhesive-mount configurations.

Die-cut chipboard and paperboard are workhorses for packaging inserts, protective dividers, and structural backing. Roylco cuts chipboard for retail packaging, automotive component trays, and industrial part separators. Our precision tooling ensures clean scores and cuts for fold-up inserts and multi-piece packaging assemblies, supporting both prototype development and production-volume runs.

Roylco cuts natural and synthetic leather for automotive trim, apparel components, and specialty interior applications. Leather die cutting demands sharp tooling and controlled press pressure to produce clean edges without stretching or distortion. Common applications include automotive seat trim inserts, console cover panels, apparel reinforcement patches, and decorative components. Prototyping services are available for new leather programs.

Die-cut cardstock and paper materials support packaging, labeling, and specialty printing applications. Roylco cuts single- and multi-ply paper-based materials in complex shapes with accurate, clean edges. Applications include retail packaging windows, custom gaskets, protective interleaves, and specialty print inserts. We support short-run prototypes and high-volume production programs alike.