Flash Cutting / Knife Cutting

KLINGER IGI, Inc.'s flash / knife cutting capabilities are provided by large-format CNC machines, some of which are equipped with multiple cutting heads and router functionality.

The process:

Tangential and oscillating knifes under computer control can precisely cut a wide variety of flexible and semi-rigid materials with a high degree of accuracy.   When augmented by an integrated heavy-duty router, versatility is achieved so that the broadest possible range of materials (including rigid) may be used to create myriad 2D and 3D products.

The advantages of Flash / Knife Cutting are numerous.  Among them are:

  • Quick turnaround on prototypes and production runs.
  • Elimination of costly and time-consuming tooling.
  • Large work envelopes for large runs.
  • Accurate cutting of sheets of varying thicknesses, improving material utilization and part yield.
  • When combined with the integrated router head, versatile precision cutting of a wide variety of materials from plastics and foams to compressed fiber and other non-metallics, both standard and exotic.
  • Precise cutting of complex shapes with high degree of accuracies (up to +/-.005) through the use of CNC robotics.
  • Minimal material waste, utilizing part nesting to reduce overall cost.
  • No material distortion or degradation (burning, crushing, chipping and fracturing) that may occur with other cutting methods, such as laser or die-cutting.
  • Superior, burr-free edge quality reduces need for secondary finishing or other post-machining work.
  • Thicknesses up to 5" depending on material.
  • Rapid standard turnarounds of 48 hours or less.

Industries served include:

  • Aerospace
  • Automotive
  • Computers
  • Consumer Products
  • Electronics
  • Homeland Security
  • Medical
  • Military
  • Transportation


Foam Products

  • Closed cell
  • EVA
  • Ether
  • High Density Urethane
  • Polyethylene
  • PVC


  • Acrylics
  • High density
  • Kapton®
  • Kevlar®
  • Low density
  • Plexiglas®
  • Polycarbonate
  • Teflon®

Compressed Sheet

  • Asbestos-free compressed fiber
  • PTFE


  • Butyl
  • EPDM
  • Buna-N®
  • Silicone
  • Neoprene
  • Nitrile
  • Viton®
  • Hypalon®


  • Fiberglass
  • Laminates
  • Phenolics
  • Wax