FABRICATION & ASSEMBLY

RF Welding

One of the best advantages of Biothane coated webbing is that it is RF weldable instead of sewing. During the RF welding process, the coating surfaces bond together to create a super strong weld that is not only cleaner than stitching but in most cases it is stronger because there is no penetration and perforation of the internal webbing like there is with stitching. We have the most modern RF welding machines available on the market that allow us to know we are producing wholesome welds on each part. Our team of tooling designers have developed standardized designs tailored to our webbing. We are able to produce a finished part that is clean, smooth and consistent and we can put any artwork, lot numbers/dates or decoration directly into each weld permanently.

To get started we need, a sample, drawing or sketch, specification and test plan. Minimums typically range from 250 to 10,000 parts depending on project scale and complexity. Set up costs can vary widely from $2,500 up $25,000 depending on complexity, scale and available tooling.

BioThane RF Welding Overview

Die Cutting

If clean holes and ends and precision tolerances are critical, consider using our die cutting service. Our proprietary die-cutting process incorporates an engineered feed and centering system capable of precision tolerances and little to no fray in the holes and ends.

To get started we need, a sample, drawing or sketch, specification and test plan. Minimums for Die Cutting are typically 5,000 parts and the process is dynamic enough to handle 1,000 or > 100,000 piece orders. One-time set-up fee for this process is typically $1,000 but varies with complexity.

BioThane Die Cutting Overview

Cutting Services

We can straight or angle cut lengths of BioThane® within 0.010”. Hot and cold
cutting options are available.

To get started we need, a sample, drawing or sketch, specification and test plan. Minimums
for this service are typically 500 pieces but vary depending on length and webbing.

Sewing

We always recommend RF welding over stitching but sometimes people want to see the stitches to believe the strength. For this, we have the most modern programmable sewing machines. We understand the role of choosing the correct thread and machine set up necessary to sew accurately, cleanly and correctly on a coated webbing.

To get started we need, a sample, drawing or sketch, specification and test plan. Minimums typically range from 250 to 10,000 parts depending on project scale and complexity. Set up costs are typically less than $1,000.

Heat Transfer & Hot Stamping

Applying your information or brand to the surface of BioThane can be done with our modern hot stamp printers. Add color and contrast by using solid color foil or multi-colored decals. Or we can simply make a hot stamp with no color.

To get started we need, artwork (Corel, Adobe Illustrator, or DXF files), sample, drawing, specification, and test plan. Minimums typically follow whatever cutting process is used. Set up costs typically range from $500 to $10,000 depending on complexity, scale, foil or decal choice and webbing choice.

Laser Cutting

With a massive 52” X 50” cutting area, our new CO2 laser is capable of a precision cut of any shape in our coated webbing and sheeting products. This machine is great for low-volume production runs that need completely sealed precise cut outs and ends Or.. clean, intricate and permanent artwork. The true super power of this machine comes out in the design and prototyping phase. No shape is off the table. The only limit is imagination.

To get started we need, sample, drawing (DWG, DXF, Corel), specification and test plan. For Small Production Orders… Minimums are typically 10 to 100 parts. Maximum is typically 1,000 to 5,000 parts depending on length, belt choice, and complexity. One time set up fee is typically <$500.

For Rapid Prototypes… Minimum is 1. Prototype fees typically range from $50 to $500 per part and vary depending on complexity, date needed, additional fab needed and belt choice.