400-867-1999
A Bangkok factory produces TPE and XPE automotive floor mats for local dealerships and regional exporters. Style turnover is fast and order sizes are shrinking, which broke their old business model.
Challenges: each new mat model required a steel die — weeks of waiting and high tooling cost; small batch orders made dies uneconomical, so they had to refuse quick, low-volume jobs; and printed or embossed patterns on mats shifted during cutting, causing misalignment and scrap.
Our solution:
1. Die-free digital cutting — CAD-to-part directly, new models sampled the same day, no steel die at all;
2. CCD vision alignment — camera-based positioning keeps cutting aligned to printed patterns and contours, eliminating run-out;
3. Intelligent nesting — parts packed tight across the sheet to cut material cost per mat;
4. Oscillating knife cold cutting — clean edges on TPE/XPE without melting or burrs.
Results: die cost dropped to zero; same-day sampling let them quote new models instantly; small-batch and custom orders became profitable instead of being refused; and pattern misalignment scrap fell sharply.
Customer's words: "The die used to be the bottleneck for everything — cost, speed, flexibility. Without dies, we say yes to small orders now, and the vision system keeps every print perfectly aligned."