Introduction
Wearable technology and stick-to-skin products are revolutionizing healthcare, fitness, and personal wellness. From continuous glucose monitors (CGMs) to smart patches and ECG sensors, flexible materials that safely adhere to the skin are critical. Precision die-cutting is at the heart of creating these complex, skin-safe adhesive components.
What Is Die-Cutting?
Die-cutting is a precision converting process used to cut flexible materials into specific shapes using steel dies or digital cutting systems. It is essential for producing adhesive layers, protective films, foam cushioning, release liners, and more.
Why Die-Cutting Matters for Wearables & Stick-to-Skin Products
- Biocompatible adhesives that are gentle on skin
- Ultra-thin materials for flexibility and comfort
- Complex multilayer constructions
- Consistent, burr-free edges
- Custom shapes for different anatomies
Die-cutting enables tight tolerance control, high-volume scalability, and cleanroom converting to meet medical-grade requirements.
Common Materials Used
- Medical-grade adhesives: acrylic, hydrogel, silicone
- PU films and non-woven fabrics
- Foams (PE, PU)
- Release liners
- Conductive and EMI shielding materials
Typical Applications
- Medical wearables: ECG/EEG electrodes, biosensors
- Fitness trackers and smart patches
- Drug delivery patches
- Beauty/cosmetic strips
- Wound care adhesives and dressings
Die-Cutting Capabilities for Skin-Adhesive Products
Yousan New Materials offers:
- Rotary and flatbed die-cutting
- Laser and kiss-cutting
- Multilayer lamination and assembly
- Cleanroom processing (ISO Class 1000)
- Biocompatibility material sourcing and testing
Key Considerations for Product Developers
- Skin Compatibility: Compliant with ISO 10993
- Breathability vs. Adhesion: Balanced comfort and performance
- Wear Time: Short-term or extended-wear adhesives
- Moisture Resistance: Hydrophobic or sweat-wicking layers
- Gentle Removal: Low-residue and pain-free adhesives
Why Choose Yousan?
At Yousan New Materials, we provide:
- Decades of converting experience
- Rapid prototyping & scalable production
- Medical-grade raw materials
- Custom die-cut solutions for wearables and healthcare
Conclusion
Die-cutting is a critical enabler of wearable and stick-to-skin technologies. With the right materials, cleanroom practices, and converting expertise, manufacturers can create safe, effective, and user-friendly products.
Need help developing your next wearable adhesive solution? Contact Yousan today to start your custom project.
If you would like to learn more about Yousan adhesive tapes, please visit our website at www.ysdiecut.com