Ward & Kennedy supplies businesses nationwide with traditionally die-cut and high-precision digitally cut Hypalon. From straps and liners to inflatable boats and everything in between, you can trust Ward & Kennedy’s nearly 100-year history for fast turnaround times and dedicated service and support.
Hypalon is a synthetic rubber known for its resistance to UV exposure, weathering, and chemicals, along with strong flexibility and durability. It's widely used in marine, roofing, and industrial applications where materials are exposed to sun, saltwater, or harsh outdoor conditions over long periods.
Common products made from Hypalon include:
Hypalon's thickness, fabric reinforcement, and tear strength directly affect how it performs during cutting, from blade pressure to edge consistency.
| Property | Description |
|---|---|
| Thickness | Heavier Hypalon requires more cutting force and sharper blades for clean edges |
| Fabric reinforcement | Many products use Hypalon coated onto nylon or polyester, so both layers must cut evenly together |
| Tear resistance | High tear strength can dull blades faster and requires consistent cutting pressure |
| Flexibility | Moderate stretch means the material needs to be held flat to avoid distorted cuts |
| Heat sensitivity | Hypalon can release fumes under heat-based cutting, making blade-based methods more common |
| Seam bondability | Cut edges need to stay clean and consistent since panels are typically glued or heat-welded together |
slices completely through the material, and both digital cutters and traditional dies can perform it depending on thickness and volume.
Perforation creates a line of small cuts for easy hand separation, achievable by both die cutting and digital cutting.
Digital cutting is the primary method used for most Hypalon applications, since products like inflatable boat panels, marine covers, and roofing membranes are typically large, custom shapes rather than repeated small parts. CNC knife cutting allows manufacturers to work directly from digital patterns for each boat model or panel size without the cost of building a die, which would be impractical for shapes that vary by product.
Die cutting is still used for smaller, uniform Hypalon components, such as gaskets or seals, where the same shape is produced repeatedly. In those cases, the upfront tooling cost is offset by faster cutting speeds and lower per-unit costs once production volume is 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.
