In the production of sanding discs, the cutting process plays a critical role in determining product quality and customer satisfaction. Recently, one of our clients reported a recurring issue: mechanical die-cutting caused sharp beveled edges on the sanding discs, resulting in customer complaints and mass returns.

This issue highlights the importance of choosing the right cutting technology. Laser cutting offers a cleaner, safer, and more precise alternative that eliminates the risks associated with traditional punching.

Common Problem: Sharp Beveled Edges from Die-Cutting

Conventional die-cutting uses high-pressure mechanical molds to punch through abrasive materials. While effective for large-volume production, this method often introduces problems such as:

• Sharp, slanted (beveled) disc edges

• Burrs, edge fraying, and surface deformation

• Reduced product safety and inconsistent grinding contact

• Increased machine vibration during high-speed sanding

In some cases, sanding discs with poorly cut edges are considered defective, leading to customer dissatisfaction or even product recalls.

Why Laser Cutting Is the Better Choice

Laser cutting uses a non-contact, high-precision thermal cutting process, ideal for modern sanding disc manufacturing. Especially for hook & loop discs, PSA discs, or multi-hole sanding discs, laser cutting offers unparalleled advantages:

✅ Perfectly smooth and burr-free edges
✅ No beveled edge – improves safety and consistency
✅ Precise control over disc size and roundness
✅ Support for custom hole patterns and contours
✅ No mold wear, no tool change, low maintenance
✅ Eco-friendly – no waste from worn-out dies

Whether you’re cutting paper-backed, cloth-backed, PET or nonwoven abrasive materials, laser cutting ensures consistent quality across batches.

Case Study: From Product Returns to Stable Production

A client in the metal polishing industry was using die-cutting machines for sanding disc production. However, the sharp-edged discs caused finger injuries during manual installation and were rejected by their end customer. After switching to our Coptics Laser Cutting System, the results were immediate:

• Smooth, safe, and clean disc edges

• No slant or taper on disc profiles

• Improved grinding performance and product acceptance

• Zero returns and 96%+ customer satisfaction rate

Laser technology not only solved the bevel issue—it became a key factor in upgrading the client’s product line.

Industries & Materials We Serve

Our laser cutting systems are suitable for a wide range of abrasive product applications:

• Metal polishing discs

• Wood sanding pads

• Automotive surface prep discs

• Wind turbine composite grinding tools

Compatible with materials such as abrasive paper, cloth-backed abrasives, PET composites, hook-and-loop materials, and PSA-backed sanding sheets.

Conclusion: Upgrade Your Sanding Disc Cutting with Laser Precision

In today’s competitive market, precision and consistency are the keys to brand reputation and customer retention. If you're facing issues with beveled edges, burrs, or low-quality finishes from die-cutting, now is the time to explore laser cutting as a modern solution.

Coptics provides tailored laser cutting systems designed for abrasive material processing—delivering clean edges, customizable shapes, and superior quality control.