Cutting and Fabricating Flexible Magnetic Materials: A Practical Guide

Flexible magnetic materials are widely used because they can be printed, laminated, slit, cut, die-cut and converted into an enormous range of finished products.

But flexible magnetic sheeting does not behave exactly like paper, vinyl, plastic film or foam.

The magnetic compound contains a high concentration of mineral magnetic particles within a flexible binder. This gives the material useful magnetic properties, but it can also affect cutting force, tool wear, edge quality, equipment settings and production speed.

The best fabrication method therefore depends on the complete material construction, thickness, finished dimensions, required tolerances, production volume and downstream application.

Table of Contents

• 1. Why Flexible Magnetic Material Cuts Differently
• 2. Start With the Complete Material Construction
• 3. Knife Cutting
• 4. Guillotine Cutting
• 5. Slitting Rolls and Strips
• 6. Die Cutting
• 7. Kiss Cutting
• 8. Tool Wear and Maintenance
• 9. Edge Quality and Finishing
• 10. Cutting Adhesive-Backed Magnetic Material
• 11. Cutting Printed and Laminated Magnetic Graphics
• 12. Tolerances, Registration and Dimensional Stability
• 13. Automating Flexible Magnet Conversion
• 14. CO₂ Laser Cutting: Important Safety Limitations
• 15. How to Choose the Right Cutting Method
• 16. Production Qualification Checklist
• 17. Common Fabrication Mistakes
• 18. Frequently Asked Questions

---

1. Why Flexible Magnetic Material Cuts Differently

Flexible magnetic sheeting is generally a composite material rather than a simple polymer film.

Its construction typically includes magnetic ferrite particles dispersed within a flexible binder.

Depending on the product, additional layers may include:

• a printable vinyl or polymer face;
• a PET or other printable film;
• a pressure-sensitive adhesive;
• a release liner;
• a protective coating;
• a laminate;
• a back coating.

The mineral content of the magnetic layer can make the material more abrasive than many conventional sign and graphic substrates.

This can affect:

• blade life;
• cutting force;
• production speed;
• edge quality;
• tool temperature;
• machine setup;
• maintenance frequency.

For the fundamentals of flexible magnetic construction, see SSKC-026 — Flexible Magnetic Sheeting Explained.

2. Start With the Complete Material Construction

Before choosing a cutting method, identify exactly what is being converted.

A plain 15 mil magnetic sheet is not the same fabrication problem as:

• a 30 mil printable magnetic sheet;
• a magnetic material with pressure-sensitive adhesive;
• a laminated magnetic graphic;
• a thin pre-magnetized digital-print sheet;
• a magnetic strip with release liner;
• a multi-layer magnetic assembly.

Important questions include:

• What is the magnetic thickness?
• What is the total finished thickness?
• Is there an adhesive?
• Is there a release liner?
• Is there a printable surface?
• Has the product already been printed or laminated?
• What finished tolerance is required?
• How many pieces must be produced?
• Will the finished part need clean cosmetic edges?

3. Knife Cutting

Knife cutting is one of the simplest methods for converting flexible magnetic sheet and is particularly useful for prototypes, short runs and straightforward shapes.

Depending on material thickness and construction, possible equipment may include:

• utility knives;
• heavy-duty knives;
• rotary cutters;
• digital flatbed cutting systems;
• drag-knife systems;
• oscillating knife systems.

Manual knife cutting

Thin magnetic sheet can often be scored or cut using a suitable sharp blade and a straightedge.

Multiple controlled passes may provide a cleaner result than attempting to force the blade through the material in a single pass.

Important safety considerations include:

• using a stable cutting surface;
• keeping hands away from the cutting path;
• using a suitable straightedge;
• replacing dull blades;
• controlling the material so it does not shift.

Digital knife cutting

Automated knife systems can provide greater repeatability for printed graphics, contour-cut parts and moderate production volumes.

Settings may need to be adjusted for:

• blade type;
• blade depth;
• cutting pressure;
• cutting speed;
• number of passes;
• material thickness;
• printed or laminated surface;
• presence of adhesive and liner.

Always qualify settings using the exact production construction.

4. Guillotine Cutting

Guillotine or shear cutting can be an efficient method for producing straight cuts in sheet-form magnetic material.

It can be particularly useful for:

• squaring sheets;
• cutting rectangular signs;
• reducing large sheets into production sizes;
• producing repeated straight-edge dimensions.

Important variables include:

• material thickness;
• blade sharpness;
• machine rigidity;
• sheet hold-down;
• cutting clearance;
• stack height;
• finished tolerance.

Trying to cut too many magnetic sheets simultaneously can increase cutting force and may reduce dimensional consistency or edge quality.

5. Slitting Rolls and Strips

Slitting is commonly used to convert wide magnetic rolls into narrower rolls or strips.

Applications can include:

• magnetic strip;
• label stock;
• warehouse identification;
• display components;
• adhesive-backed magnetic tape;
• industrial converted parts.

Slitting equipment may use different blade systems depending on the material and production requirements.

Important factors include:

• roll tension;
• web tracking;
• blade geometry;
• blade spacing;
• magnetic thickness;
• adhesive construction;
• release liner;
• finished strip width tolerance;
• roll winding quality.

The magnetic material’s weight can make tension control more important than with lightweight films.

For adhesive-backed constructions, adhesive buildup on blades may also need to be monitored.

6. Die Cutting

Die cutting is highly useful when large quantities of magnetic parts must be produced repeatedly in a defined shape.

Applications can include:

• circles;
• rectangles;
• custom shapes;
• labels;
• promotional magnets;
• industrial components;
• magnetic pads;
• assembled parts.

Possible tooling systems include steel-rule dies and other production die-cutting systems appropriate to the material.

Die-cut performance depends on:

• magnetic thickness;
• material hardness;
• facing material;
• adhesive construction;
• liner;
• die geometry;
• press pressure;
• production volume.

The abrasive nature of the magnetic compound can increase die wear over time.

For high-volume production, tooling life should be included in the economics of the conversion process.

7. Kiss Cutting

Kiss cutting is particularly useful for adhesive-backed magnetic products.

The objective is to cut through selected upper layers while leaving the release liner substantially intact.

A simplified construction might be:

Flexible Magnet → PSA → Release Liner

A kiss-cut process may cut through:

Magnet + PSA

while preserving:

Release Liner

This allows individual parts to remain on a common liner until final assembly or application.

Successful kiss cutting requires careful control of:

• cut depth;
• die height or blade setting;
• material thickness variation;
• liner thickness;
• adhesive behavior;
• press pressure;
• registration.

Too little penetration can leave parts connected. Too much can cut through or weaken the liner.

8. Tool Wear and Maintenance

Flexible magnetic compounds contain a high percentage of mineral particles, and these particles can be abrasive to cutting tools.

Compared with ordinary vinyl, paper or many plastic films, magnetic material may accelerate wear on:

• knife blades;
• rotary cutters;
• slitter blades;
• steel-rule dies;
• digital cutting tools.

A dull tool can create:

• rough edges;
• increased cutting force;
• dimensional variation;
• material distortion;
• incomplete cuts;
• additional stress on equipment.

9. Edge Quality and Finishing

The required edge quality depends on the finished application.

An internal industrial component may tolerate a different edge finish than a visible retail graphic.

Evaluate:

• edge straightness;
• burrs or roughness;
• surface-face lifting;
• adhesive squeeze-out;
• liner integrity;
• corner quality;
• cosmetic appearance.

Rounded corners can be useful in some finished magnetic graphics because sharp corners may be more vulnerable to lifting or damage during handling.

However, corner geometry should be determined by the application rather than treated as a universal requirement.

10. Cutting Adhesive-Backed Magnetic Material

Adding a PSA and release liner changes the converting process.

Possible issues include:

• adhesive buildup on tooling;
• liner tearing;
• adhesive displacement;
• edge contamination;
• variation in total thickness;
• difficulty separating finished parts;
• premature liner release.

Tool cleaning may need to become part of normal production maintenance.

The PSA itself must also remain suitable for the intended substrate after fabrication.

For adhesive selection, see SSKC-037 — Adhesive-Backed Flexible Magnets: How to Choose the Right PSA.

11. Cutting Printed and Laminated Magnetic Graphics

Printing and laminating the material can change the way it behaves during cutting.

The finished construction may become:

• thicker;
• stiffer;
• heavier;
• less conformable;
• more sensitive to cracking or surface damage;
• more difficult to register precisely.

When contour cutting printed magnetic graphics, consider:

• print-to-cut registration;
• dimensional change during printing;
• laminate thickness;
• graphic orientation;
• cutting pressure;
• edge appearance;
• finished magnetic contact.

For printer and media compatibility, see SSKC-035 — Printable Magnetic Sheeting: How to Choose the Right Material for Your Printer.

12. Tolerances, Registration and Dimensional Stability

Flexible magnetic material is still a flexible composite.

Dimensions can therefore be influenced by:

• temperature;
• material tension;
• roll memory;
• printing heat;
• lamination;
• storage conditions;
• cutting pressure;
• handling.

For parts requiring close dimensional tolerances, establish measurement and conditioning procedures.

Important questions include:

• At what temperature should dimensions be verified?
• Is the material measured flat or under tension?
• Is tolerance required before or after printing?
• Does lamination change the dimensions?
• Will the part be assembled into another component?

Do not specify tighter tolerances than the complete manufacturing process can consistently maintain.

13. Automating Flexible Magnet Conversion

As volumes increase, automation can improve productivity and repeatability.

Potential systems can include:

• roll-fed slitters;
• automatic sheet cutters;
• digital cutting tables;
• rotary die cutters;
• flatbed die-cutting systems;
• laminating and cutting lines;
• vision-registration systems;
• automated rewind systems.

Before automating, understand the process that already works manually or at low volume.

Automation should control variables such as:

• web tension;
• feed alignment;
• cut depth;
• registration;
• tool wear;
• liner handling;
• waste removal;
• finished-part collection.

14. CO₂ Laser Cutting: Important Safety Limitations

Laser cutting requires a fundamentally different safety evaluation from mechanical cutting.

A material that can be cut safely with a knife, die or shear must not automatically be considered safe for a CO₂ laser.

Laser processing thermally decomposes the material.

The gases, vapours, particulates and residues produced depend on the complete chemical composition of every layer in the construction.

This can include:

• the magnetic binder;
• printable films;
• vinyl facings;
• coatings;
• pressure-sensitive adhesives;
• release liners;
• laminates;
• inks and printed coatings.

Why PVC and chlorine-containing materials are a particular concern

PVC and other chlorine-containing materials should not be processed in a CO₂ laser unless the equipment manufacturer and material manufacturer explicitly establish that the complete construction is suitable for that process.

Thermal decomposition of chlorine-containing materials can generate hazardous and highly corrosive emissions, including hydrogen chloride.

These emissions can present risks to:

• operators;
• ventilation systems;
• laser optics;
• metal components;
• electronics;
• the surrounding workplace.

“PVC-free” does not automatically mean “laser safe”

This distinction is important.

A material can be free of PVC and still contain other components that are unsuitable for thermal laser processing.

Before considering laser cutting, confirm:

• complete chemical composition;
• whether chlorine-containing components are present;
• adhesive chemistry;
• surface-film composition;
• coating composition;
• laser-equipment manufacturer requirements;
• ventilation and filtration requirements;
• applicable workplace safety requirements.

An SDS can provide useful hazard information, but it may not always disclose every component needed to establish laser-processing suitability. When necessary, obtain written confirmation from the material manufacturer.

15. How to Choose the Right Cutting Method

Requirement	Possible Starting Method
Prototype or very short run	Knife or digital cutting
Straight rectangular sheets	Guillotine or shear
Narrow rolls or strips	Slitting
High-volume repeated shapes	Die cutting
Adhesive-backed parts on common liner	Kiss cutting
Printed contour shapes	Vision-assisted digital cutting or suitable die cutting
High-volume roll conversion	Automated slitting, rotary die cutting or converting line
CO₂ laser requested	Confirm full composition and explicit laser compatibility first; otherwise use a mechanical method

16. Production Qualification Checklist

Before releasing a flexible magnetic conversion job to production, confirm:

• Material identification: Exact magnetic product and construction.
• Thickness: Magnetic thickness and total finished thickness.
• Facing: Plain, printable, laminated or coated.
• Adhesive: Presence, type and liner construction.
• Finished dimensions: Including acceptable tolerances.
• Cutting method: Knife, shear, slitter, die or other qualified process.
• Tool condition: Sharpness and expected tool life.
• Edge quality: Cosmetic and functional requirements.
• Registration: Required alignment to printing or other features.
• Production volume: Prototype, short run or high-volume production.
• Waste handling: Scrap removal and recycling/disposal requirements.
• Final application: Confirm the converted piece still meets magnetic, adhesive and environmental requirements.

For overall material selection, see SSKC-032 — How to Choose Flexible Magnetic Sheeting for Your Application.

17. Common Fabrication Mistakes

Mistake 1: Treating magnetic material like ordinary vinyl

The magnetic compound can require different cutting forces, blades and maintenance intervals.

Mistake 2: Using dull tooling

Dull blades can reduce edge quality and increase material distortion.

Mistake 3: Ignoring the complete construction

A laminate, PSA or liner can completely change the appropriate process settings.

Mistake 4: Cutting too large a stack

The machine may complete the cut while dimensional accuracy or edge quality deteriorates.

Mistake 5: Ignoring tool wear in production costing

Magnetic materials can consume tooling faster than conventional graphic films.

Mistake 6: Using identical settings for every thickness

15 mil, 20 mil and 30 mil constructions can require different cutting parameters.

Mistake 7: Qualifying the material before printing but not after printing

Printing, heating and lamination can change thickness, stiffness and dimensional stability.

Mistake 8: Assuming PVC-free means laser safe

Laser safety depends on the complete material construction, not a single excluded ingredient.

Mistake 9: Laser cutting material of unknown composition

If the binder, coatings, adhesive or facing cannot be positively identified, laser compatibility has not been established.

18. Frequently Asked Questions

Can flexible magnetic sheeting be cut with a knife?

Many flexible magnetic materials can be mechanically cut with an appropriate sharp knife, particularly in thinner constructions and short runs. The suitable blade, pressure and number of passes depend on the exact material thickness and construction.

Can magnetic sheeting be cut with a guillotine?

Yes, many sheet-form flexible magnetic materials can be cut using suitable guillotine or shear equipment. Machine capability, material thickness, blade condition and stack height should be qualified.

Can flexible magnetic material be slit into narrow strips?

Yes. Roll-form flexible magnetic material is commonly slit into narrower rolls and strips using suitable industrial slitting equipment.

Can magnetic sheeting be die-cut?

Yes. Flexible magnetic materials can commonly be die-cut into repeated shapes. Tool design, press setup and tool wear should be matched to the material construction and production volume.

Can adhesive-backed magnetic sheet be kiss-cut?

Yes, many adhesive-backed constructions can be kiss-cut so the magnetic material and PSA are cut while the release liner remains substantially intact. Accurate depth control is important.

Does flexible magnetic material wear out cutting blades quickly?

It can accelerate blade wear compared with many conventional paper, vinyl and film products because the magnetic compound contains a high concentration of mineral particles.

Can printable magnetic sheeting be contour-cut?

Yes, depending on the construction and equipment. Printed and laminated magnetic graphics may be contour-cut using suitable digital cutting systems or other qualified methods.

Can flexible magnetic sheeting be cut with a CO₂ laser?

Do not assume that it can. CO₂ laser suitability depends on the complete chemical composition of the magnetic binder, facing, coatings, adhesive, liner and any laminate. If chlorine-containing materials such as PVC are present, or if the full composition is unknown, the material should not be treated as laser-compatible.

Is PVC-free magnetic sheeting automatically safe for laser cutting?

No. PVC-free only confirms the absence of PVC if the claim is properly supported. Other components may still make the material unsuitable for laser processing. Full construction and equipment guidance must be reviewed.

What is the safest alternative when laser compatibility is unknown?

Evaluate a suitable mechanical method such as knife cutting, guillotine cutting, slitting, die cutting or digital cutting.

Should I test the cutting process before full production?

Yes. Test the exact finished construction, including printing, laminate, PSA and liner where applicable. Confirm dimensional accuracy, edge quality, tooling performance and the final application before full production.

---

Safety & Production Reminder

Always review the complete product construction before selecting a fabrication method.

Mechanical cutting parameters should be qualified for the exact magnetic thickness, facing, adhesive and liner.

For laser processing, positive identification of every relevant material layer is essential. If the composition or laser-processing suitability is uncertain, do not assume compatibility.

---

Continue Learning About Flexible Magnetic Materials

Learn how flexible magnetic sheeting is constructed in SSKC-026 — Flexible Magnetic Sheeting Explained.

Compare common magnetic thicknesses in SSKC-031 — 15 mil vs 20 mil vs 30 mil Magnetic Sheeting.

Use SSKC-032 — How to Choose Flexible Magnetic Sheeting for the overall material-selection process.

For printable materials, see SSKC-035 — Printable Magnetic Sheeting: Choosing the Right Material for Your Printer.

For adhesive-backed constructions, see SSKC-037 — Adhesive-Backed Flexible Magnets: How to Choose the Right PSA.

---

Need Help Converting Flexible Magnetic Material?

Tell us the magnetic material, thickness, roll or sheet format, finished dimensions, required tolerances, printing or laminate construction, adhesive requirements, cutting method and production quantity.

If laser processing is being considered, provide the exact product construction so material compatibility can be reviewed before the process is approved.

Simple Signman — a leading Canadian source for flexible magnetic materials and neodymium magnets.

Sharing our magnetic expertise since 1969.