Eight Advanced Process Technologies That Shape Our Products
We offer tried-and-true streamlined services that help our customers and partners move their innovative projects into the future.
A product development process used to produce laminates by bonding foam/fabric or foam/film by passing the foam over an open flame. Exposure to the flame creates a thin layer of molten polymer on the foam surface that is brought into contact with the second layer under pressure to develop a bond between the two surfaces.
- Width capability to 82”
- Pinhole-free barrier materials
- Flame retardant material handling expertise
- Multiple-layer laminates produced in a single pass
Hot Melt Rotogravure Lamination
We implement thermoplastic or reactive adhesives through direct printing of moving webs via anilox gravure roll, which is then combined under controlled conditions. Shawmut maintains a portfolio of applicator rolls with various discontinuous patterns to achieve a diverse range of adhesive laydowns and coverages that influence physical properties and performance. This textile technology platform can process advanced materials utilizing a roll coating methodology, enabling the application of a continuous coating of adhesive or polymeric compounds.
- 80” overall width
- Thermoplastic adhesives (polyester, polyamide, polyolefins, and polyurethane)
- Reactive adhesives (polyurethane and polyolefins)
- Pressure sensitive adhesives (rubber and acrylic)
- In-line Corona treating on one or both plies
Thermoplastic Adhesive Lamination
Thermoplastic materials available in a wide range of available formats are applied on thermal lamination equipment, including oil heated drums with Teflon coated conveyor belts and Flatbed systems are utilized to create adhesion between similar or dissimilar substrates.
- Width capability up to 76”
- Pressure sensitive adhesives
- Powdered adhesives
- Web adhesives
- Dry film adhesives
- Fusible substrates
- Full range of polymers (nylon, polyester, polyolefins, and polyurethanes)
- Temperatures up to 400F
Water-based Adhesive Lamination
Application of water-based laminate adhesives via direct gravure printing method incorporates a variety of options using patterned anilox rolls. In this process, excess adhesive on the applicator is metered off using a doctor blade. At the same time, one substrate is printed with glue under controlled conditions and then combined with a second layer in the “wet state.” The material composite is then dried and cured through heat and pressure through a series of heated rolls.
- Width capability to 72”
- Direct gravure coating
- Flood coat
A molten polymer such as PVC or polyurethane is fed through a die to create a profile extrusion, which is then immersed in a chilled water bath to cool and set the shape.
- Polymers (TPU and PVC)
- Decorative foils
- Clear and colored resin
Rewinding and Slitting
We offer extensive slitting capabilities, ranging from programmable Duplex Slitters to score cutters and rotary shears to a large baloney slicer. Regardless of whether a finished composite material requires removal of the edges or multiple slits from a single piece of full-width material, our engineers have developed creative and custom solutions to meet the demands of the most complex slitting requirements.
Die Cutting and Blanking
All types of cutting are available, including shuttle press for stretch sensitive headliners, roll feed presses for high volume cutting and sorting, and CNC cutting for high yield fabric utilization.
With more than 40 years of experience in the compression molding of innovative textiles and polymer substrates foams, we work with hot and cold molding processes in high-volume automated and low-volume niche production formats to deliver optimal cost-effective molding solutions.
- Small presses for low-running, low-tooling, and fast-to-start programs
- Large presses for high-volume and low-piece price alternatives
- Automated presses for one-step mold, form, and cut
Contract Manufacturing and Value-Added Services
We have developed a broad range of complimentary value-added product development processes to provide a product to customers in a state that is enhanced beyond the traditional laminate. We have established contract manufacturing capabilities from design through packaging to assist our customers by providing semi-finished or finished products. These advanced process technologies can be leveraged for use around the world.
- Reverse engineering
- Materials sourcing
- Computer-aided design
- Die cutting
- RF welding
- Ultrasonic welding
- Silicone coating
- C – folding
West Bridgewater, Massachusetts
Port Huron, Michigan
Middletown, New York
Lughoff, South Carolina
Burlington, North Carolina
Laguna Beach, California