Ward & Kennedy supplies businesses nationwide with traditionally die-cut and high-precision digitally cut corrugated plastic. From lightweight packaging to yard signs and everything in between, you can trust Ward & Kennedy’s nearly 100-year history for fast turnaround times and dedicated service and support.
Corrugated plastic is a lightweight, rigid material made from polypropylene or polyethylene, formed with a fluted internal structure similar to corrugated cardboard. It's widely used across signage, packaging, and protective covering applications, particularly where durability, water resistance, and weather resistance are needed.
Common products made from corrugated plastic include:
Corrugated plastic's flute structure, rigidity, and heat sensitivity directly affect how it performs during cutting, from blade pressure to edge quality.
| Property | Description |
|---|---|
| Flute direction | Affects how cleanly the material scores and folds along crease lines, similar to corrugated cardboard |
| Thickness & flute size | Determines the cutting pressure needed and how easily the hollow channels crush or hold shape |
| Rigidity | More rigid than cardboard, which can require sharper blades or routing for clean edges |
| Impact resistance | Can crack rather than cut cleanly if handled too aggressively, especially in cold temperatures |
| Heat sensitivity | Can melt or warp under excessive heat, which affects settings for laser-based cutting |
| Hollow structure | Similar to corrugated cardboard, requires balanced pressure to avoid crushing the flutes during cutting |
slices completely through the material, and both digital cutters and traditional dies can perform it depending on thickness and volume.
Creasing forms a fold line without cutting through the material, handled well by digital cutters through adjustable pressure and by dies fitted with the right rule type.
Digital cutting works well for prototyping corrugated plastic products and producing custom signage, since designs like real estate signs or campaign graphics often vary by client and require quick turnaround without tooling costs. CNC routing or digital knife cutting allows precise shapes and stake slots to be cut directly from a design file.
For production runs, die cutting is the standard approach, especially for high-volume identical signs like election or promotional yard signs. The upfront tooling cost is offset by faster cutting speeds and lower per-unit costs once the design is finalized and quantities are high enough to justify the die.
At our facility in Milwaukee, WI, our team of designers and fabricators can help bring your vision to life. Whether you have existing design files or assistance with their creation, we’re here every step of the way.
Along with fabrics, we die cut materials like:
Ward & Kennedy has been designing, fabricating, and supplying industries all over the world since we were founded in 1928. Whether you’re in our Wisconsin backyard or located across the world in Asia, we can supply your die cut materials.
Along with fabricating parts for businesses across America, we supply them with the necessary tools, supplies, and gear to keep them running at full capacity. We stock abrasives, adhesives, PPE, and more from major brands like 3M, Dynablade, Superior Glove, Wendt and Mirka.
