Ward & Kennedy supplies businesses nationwide with traditionally die-cut and high-precision digitally cut plastics. From toys and games to custom-cut parts from sheet extrusions and everything in between, you can trust Ward & Kennedy’s nearly 100-year history for fast turnaround times and dedicated service and support.
Plastics are a broad category of synthetic and semi-synthetic materials, ranging from rigid sheets to flexible films, valued for their durability, versatility, and cost efficiency. They're used across nearly every industry, including packaging, automotive, signage, medical, and consumer goods, wherever a lightweight and customizable material is needed.
Common products made from plastics include:
Plastic properties vary widely by type, but rigidity, thickness, and heat sensitivity are the factors that most directly affect how a given plastic performs during cutting.
| Property | Description |
|---|---|
| Rigidity | Rigid plastics like acrylic or polycarbonate often require routing or laser cutting, while flexible plastics can be blade cut |
| Thickness | Thicker plastic sheets need more cutting force and, in some cases, specialized tooling |
| Heat sensitivity | Thermoplastics can melt or warp under heat-based cutting, while thermosets generally resist heat better |
| Impact resistance | Brittle plastics can crack or chip if cut too aggressively or in cold conditions |
| Chemical composition | Certain plastics release fumes when cut with heat, which affects the choice between blade and laser methods |
| Clarity and finish | Optically clear plastics may need extra care to avoid scratching or clouding the cut edge |
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.
The choice between digital and die cutting for plastics depends largely on rigidity and production volume. Digital cutting, through CNC routing, laser, or knife cutting, works well for prototyping and for rigid plastics that don't respond well to traditional die cutting, since it can produce precise shapes directly from a design file without tooling costs.
Die cutting remains the better option for flexible plastics produced in high volume, such as packaging film or thin sheeting, where repeated shapes are needed. The upfront tooling cost is offset by faster cutting speeds and lower per-unit costs once the design is finalized and production quantities increase.
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.
