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Automatic Plastic Profile Cutter

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Automatic Plastic Profile Cutter

Efficient production of custom-length plastic parts - with less labor and zero waste

The Problem

A client needed a better way to produce a specific plastic part used in his product. At first glance, the part was simple — a plastic block with a rectangular cross-section and two sides angled by 3-4 degrees. However, the tricky part was this: the length needed to be variable, so the part could fit inside other plastic components of different widths.

The client initially tried injection molding the part and cutting it to size before assembly. This turned into a frustrating, wasteful process:

  • The cutting had to be done manually, consuming time and effort.
  • Variability in lengths made it hard to maintain stocks.
  • The process created significant material and labor waste.
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The Solution

We approached the problem from three angles — part redesign, production method, and custom automation.

  • Part redesign:
    We switched from injection molding to plastic extrusion, allowing the part to be produced in continuous lengths, perfect for on-demand cutting.
  • Process change:
    The switch to extrusion meant the part could be made more efficiently — and more flexibly — it's cheaper to add different widths and profiles in the future.
  • Custom machine design:
    We developed an automatic profile cutter that swings a cutting blade at a pre-set angle (3–4°), allowing clean, consistent cuts for parts of varying lengths.

The Result

The client saw immediate and long-term benefits:

  • Waste reduced significantly, both in materials and labor.
  • The cutting process is now automatic, improving speed and consistency.
  • When the client launched a new product requiring a different part width, the same machine handled it with no issues.
  • Tooling costs were drastically lower — extrusion dies are much cheaper than injection molds, making this a more scalable solution.

Facing a similar production challenge?

We design and build machines and tools that solve real manufacturing problems — fast, affordable, and built for small manufacturers.

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