Die Cutting of a Respirator Mask Exhalation Valve

At Ames Rubber Manufacturing, we specialize in working with unique materials, custom sized, and precision cut for use in a wide range of applications. Our goal is to exceed customer expectations with our high volume, precision die cutting capabilities.

In the project highlighted here, a manufacturer of Respirator Safety masks required an exhalation valve which is used in various respirator masks. Utilizing our Preco Series III M high-speed 4 post press, we produced a valve with .015″ thickness, .125″ ID, and 1.064″ OD, along with tolerances as close as + .015″. In order to prep the 40 Durometer Protein-Free Polyisoprene material for high speed kiss cutting, the Sheet Rubber & Gasketing was roll-slitted to the customer specifications. The dies were custom made to non-standard sizes, grounded flat and parallel to ensure uniform cutting. Our feed system allowed for +.005″ progression accuracy, increasing material yields. Since Polyisoprene is highly resilient, the material has to be relaxed prior to each cut cycle in order to ensure parts are not stretched and deformed. Once manufactured, each valve was inspected using in process sampling per ANSI Z 1.4 standards.

As a result, we have produced 2-3 million valves annually with in-house bagging and packaging to ensure cleanliness and dimensional stability during shipment and storage. We worked with our vendor on inventory control levels; ensuring large volumes of product were handled properly and delivered to specified locations without interruption. To learn more about our work with high volume precision die cutting, please contact us for more information or refer to the table below.