Eight Processes That
Shape Our Products
We offer tried and true streamlined services that help our customers move their innovative projects into the future.
A 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, which is then brought into contact with the secondary layer under pressure to develop a bond between the two surfaces.
- Width capability to 82”
- Pinhole free barrier materials
- Expertise handling flame retardant materials
- Multiple layer laminates produced in a single pass
Hot Melt Rotogravure Lamination
The application of thermoplastic or reactive adhesives via direct printing of moving webs via anilox gravure roll, which is then combined under controlled conditions. Shawmut maintains a portfolio of applicator rolls with a variety of discontinuous patterns to achieve diverse range of adhesive laydowns and coverages which influence physical properties and performance. This technology platform also has the ability to process materials utilizing a roll coating methodology, which enables application of continuous coating of adhesive or polymeric compounds.
- 80” overall width
- Thermoplastic adhesives (polyester, polyamide, polyolefins, polyurethane)
- Reactive adhesives (polyurethane, 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, polyurethanes)
- Temperatures up to 400F
Water-Based adhesive lamination
Application of water based adhesives via direct gravure printing method, which incorporates a variety of options using patterned anilox rolls. In this process, excess adhesive on the applicator is metered off using a doctor blade, while one substrate is printed with adhesive under controlled conditions and then combined with a secondary layer in the “wet state”. The composite is then dried/cured through the use of heat and pressure through a series of heated rolls.
- Width capability to 72”
- Direct gravure coating
- Flood coat
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, 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 requires removal of the edges or multiple slits from a single piece of full-width material, our engineers have developed creative solutions to meet the demands of the most complex slitting requirements.
Die Cutting & Blanking
All types of cutting is 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 over forty years of experience in the compression molding of 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, fast to start programs
- Large presses for high-volume, 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 processes in an effort to provide product to customers in states that have been enhanced beyond the traditional laminate. We have established contract manufacturing capabilities from design through packaging in an effort to assist our customers by providing semi-finished or finished products. These capabilities 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