Die Cutting and Sewing of Orthopedic Strap

Project description:

Die Cut Orthopedic Strap

At Elastomer Technologies we continually expand our portfolio of services to support start-to-finish production of assembled products. We have a strong history of applying different technologies to make outsourcing a cost-effective and convenient solution for our clients. Designed and manufactured for an orthopedic application, the product highlighted here consists of a die-cut nylon covered Kevlar strap sewn onto a stamped stainless steel fastener.

We managed all aspects of this project, and it served as our gateway into industrial sewing. While preparing our project plan, we came to the conclusion that acquiring sewing equipment was a good approach for us. Attaching the straps in-house gave us better control over quality and scheduling. We also saw that adding sewing capabilities had applications on other projects and would be a useful addition to our skills mix.

Another facet of this project involved sourcing the stamped metal fitting. The original specifications called for titanium however, since titanium is subject to fracture when shaped, we recommended stainless steel as an alternative. Stainless steel provided all of the required material properties for this medical application, but at a more affordable price.

Production of this product involved die cutting the strap, inserting it into the fitting, and affixing it using a heavy duty stitch pattern to create a strong and durable seam. We measured each of these components using custom inspection fixtures to ensure precise dimensional accuracy. When assembled, these high-strength straps measured 6.00″ in length x .0500″ in width and satisfied the client’s quality requirements. Since completing the initial run, we continue to produce them in lots of 50 to 500 per order.

Our ability to provide end-to-end management of this project benefited the client in terms of quality, cost, and delivery time. It also provided us with an opportunity to expand our services to better support the ongoing needs of our clients. It was a win-win all around.

If you are interested in learning more about our range of capabilities, contact us today.

Orthopedic Strap Project Details

Project Name & Description

Kevlar strap

Capabilities Applied/Processes

Die cutting, industrial sewing, sourcing stamped stainless steel parts.

Equipment Used to Manufacture Part

Clicker die cutting press, industrial sewing machine.

Overall Part Dimensions

6.0″ x .500″

Tightest Tolerances

Measured on fixture.

Material Used

Nylon covered Kevlar woven strap.

Material Finish


Industry for Use


In Process Testing/Inspection Performed

Measuring fixtures, drawing specification.


50-500 per order

Delivery/Turnaround Time

4-6 weeks.