Cutting & Lamination Processes
For Soft Goods
CNC die cutting is a high-precision, high-throughput process that enables consistent cutting of soft goods materials at scale. At AGORA, we use servo-driven CNC die cutting systems designed for speed, accuracy, and material efficiency, supporting both prototyping and full production runs.
Our CNC die cutting equipment operates with hydraulic systems, which reduce energy consumption and maintenance requirements while improving process reliability. Servo-controlled cutting heads deliver precise, repeatable cuts across a wide range of synthetic materials.
Advanced layout software and a full 360-degree cutting radius maximize material yield and minimize waste. With cutting forces up to 50 tons and cycle speeds exceeding 50 cuts per minute, this process supports materials of varying thickness and rigidity while maintaining consistent quality.
An automatic tool-changing system allows dies to be swapped in seconds, enabling rapid changeovers and efficient multi-part production. This flexibility makes CNC die cutting a cost-effective solution for both low- and high-volume programs.
- High-volume or repeatable production programs
- Maximizing material utilization and minimizing waste
- Programs requiring fast changeovers between parts or configurations
- Scaling production without sacrificing precision
LASER stands for Light Amplification by Stimulated Emission of Radiation. It is a concentrated beam of light that heats, melts, or burns through materials upon contact. Using a focused, high-energy light beam, laser cutting enables intricate geometries, tight tolerances, and minimal material distortion.
In addition to cutting, laser etching allows designs, markings, and patterns to be applied directly to materials without full material removal, making it ideal for branding, alignment marks, or functional features.
Laser cutting is a high-precision manufacturing process used to produce clean, accurate cuts and detailed features across a wide range of soft goods materials. When integrated with automation and digital workflows, laser cutting provides exceptional process consistency and control. This makes it well suited for applications requiring precise detail, delicate features, or clean edges that are difficult to achieve with mechanical cutting methods.
At AGORA, computer-controlled laser systems support both prototyping and production by delivering repeatable accuracy and refined edge quality.
- Precision cutting of complex or detailed geometries
- Clean edge finishes with minimal material fraying
- Intricate patterns, markings or etched features
- Delicate or thin materials requiring controlled cutting
- Repeatable production with high process consistency
- Synthetic fabrics and textiles
- Coated and laminated materials
- Non-woven fabrics
- Foams and flexible polymer sheets
- Certain natural materials, depending on application requirements
Both laser cutting and CNC die cutting are precision cutting methods, but each excels in different applications.
Laser cutting is frequently combined with downstream processes such as RF welding, flame lamination, and industrial sewing to create production-ready assemblies. This integrated approach ensures accuracy, consistency, and manufacturability across complex soft goods constructions.
- Laser-cut components prepared for RF-welded seams or sealed edges
- Laser-cut fabrics laminated to foams or non-wovens prior to assembly
- Etched alignment marks to support accurate welding or stitching
- Precision-cut layers assembled into multi-material soft goods systems
Waterjet cutting is a high precision cutting process that uses a focused, high pressure stream of water to cut a wide range of materials with exceptional accuracy. Waterjet cutting is used as a versatile solution for both prototyping and production, including tooling, fixtures, and repair parts, especially where material integrity and flexibility are critical.
Because waterjet cutting does not introduce heat into the material, it eliminates heat affected zones and preserves material properties and edge quality. This makes it particularly effective for cutting thick, layered, or heat sensitive materials that are difficult to process using thermal methods.
AGORA’s waterjet systems support cutting areas up to 4 ft × 4 ft, with cutting depths ranging from 0.030 inches to 8 inches depending on material. These capabilities allow us to produce precise cutouts and components across a range of sizes and thicknesses, supporting tight schedules and consistent quality.
- Thick or dense materials
- Heat-sensitive materials
- Multi-layer or composite stacks
- Complex shapes requiring clean edges
- Foam, metal, and hybrid cutouts
- Composites and laminates
- Plastics and acrylics
- Alloys and steels
- Rubber and gasket materials
- Foams and multi-layer assemblies
Flame lamination is a bonding process used to join flexible materials such as fabrics, foams, and non-woven polyesters or nylons without the need for chemical adhesives. This technique is commonly applied in soft goods manufacturing where breathability, durability, comfort, and cleanliness are critical.
Flame lamination is a fast, eco-friendly process that uses an open, controlled gas flame to slightly melt the surface of thermoplastic foam, often polyurethane, turning it into a tacky adhesive layer. This molten foam is immediately pressed against a substrate such as fabric or non-wovens using rollers, creating a strong, durable, and permanent bond upon cooling. By eliminating separate adhesives, flame lamination reduces material cost, simplifies processing, and improves production efficiency.
Flame lamination is both fast and environmentally considerate, offering a cleaner alternative to many traditional lamination methods. It is particularly well suited for applications such as headgear used to secure breathing masks and medical braces where comfort, consistency, and material integrity are essential. It is a high-speed, continuous process ideal for large-scale production, including automotive interiors and footwear.
- Bonding fabrics to flexible Polyurethane foams or polyester-based foams often preferred for their strength and open-cell structure
- Applications requiring chemical-free adhesion
- Products intended for skin contact or ergonomic comfort
- Programs requiring fast, repeatable lamination at scale
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